Rice Lake ISHIDA IP-AI User manual

IP-AI
Prepack Scale & Printer
Service Manual
PN 179840

An ISO 9001 registered company
© Rice Lake Weighing Systems. All rights reserved.
Rice Lake Weighing Systems®is a registered trademark of
Rice Lake Weighing Systems.
All other brand or product names within this publication are trademarks or
registered trademarks of their respective companies.
All information contained within this publication is, to the best of our knowledge, complete
and accurate at the time of publication. Rice Lake Weighing Systems reserves the right to
make changes to the technology, features, specifications and design of the equipment
without notice.
The most current version of this publication, software, firmware and all other product
updates can be found on our website:
www.ricelake.com

Introduction
(2)
Introduction
● Purpose of this Manual
The purpose of this manual is as reference material for the delivery, installation, repair and maintenance
of the IP-AI.
● Target Readers
This manual has been written specifically for use by our service personnel.
The use of this manual by any person other than the above is strictly prohibited.
● Related Manuals
Manual Name
Content
IP-AI Instruction Manual
Instruction Manual (included in the package of that product)
●Meanings of Signal Words
Signal Word
Meaning
Indicates a potentially hazardous situation, which, if not avoided, will
result in severe injury or death.
Indicates a potentially hazardous situation, which, if not avoided, could
result in severe injury or death.
Indicates a potentially hazardous situation, which, if not avoided, may
result in minor or moderate injury or in property damage.
Signal Word
Meaning
NOTE:
Indicates information that needs to be noted or emphasized.
Indicates the reference information.
Indicates the reference page.
It is strictly prohibited to copy or reproduce part or all of this manual without prior approval by the
copyright holder.

Introduction
(3)
Table of Contents
Revision History ....................................................................................................... 1
Introduction ............................................................................................................... 2
Chapter 1 Overview ........................................................................................... 1-1
1.1 Specifications .................................................................................................. 1-1
1.2 Features ........................................................................................................... 1-4
1.3 Name of Each Part .......................................................................................... 1-5
1.4 Dimensions ...................................................................................................... 1-6
1.5 Items Required for Installation ....................................................................... 1-7
1.6 Installation Space ............................................................................................ 1-8
1.7 Power Supply .................................................................................................. 1-9
1.8 Carry-in and Installation ............................................................................... 1-10
1.8.1 Installation Procedure Check Sheet ............................................................1-10
1.9 Setup .............................................................................................................. 1-11
1.9.1 Requirements for Setup..........................................................................1-11
1.9.2 Setup Procedure.....................................................................................1-11
1.9.3 Operation Checks...................................................................................1-13
1.9.4 Operation Explanation ............................................................................1-13
1.9.5 Issuing a Warranty..................................................................................1-13
Chapter 2 Mechanical Adjustment ....................................................................... 2-1
2.1 Removing Case Covers .................................................................................. 2-1
2.1.1 Case Body (Top) ............................................................................................2-1
2.1.2 Case Body (Left Side)....................................................................................2-1
2.1.3 Case Body (Right Side) .................................................................................2-2
2.1.4 Case Body (Rear) ..........................................................................................2-2
2.1.5 Case Body (Scale Cable)...............................................................................2-2
2.2 Replacing Prats ............................................................................................... 2-3
2.2.1 Replacing the Thermal Head.........................................................................2-3
2.2.2 Adjusting the Thermal Head Position.............................................................2-4
2.2.3 Replacing the Print Roller..............................................................................2-6
2.2.4 Replacing the Peeling Sensor........................................................................2-8
2.2.5 Replacing the Label Sensor...........................................................................2-9
2.2.6 Replacing the Head Up Sensor ...................................................................2-10
2.2.7 Replacing the Keyboard...............................................................................2-11
2.2.8 Replacing the Main Board............................................................................2-12
2.2.9 Replacing the Power Supply Board.............................................................2-13
2.2.10 Replacing the Motor...................................................................................2-14
2.2.11Adjusting the Belt Tension..........................................................................2-15
2.2.12 Replacing the Scale Cable.........................................................................2-16
2.2.13 Adjusting the Ball Catch Position...............................................................2-17
2.3 Replacing the Display Unit ........................................................................... 2-18
2.3.1 Replacing the Display Board........................................................................2-18
2.3.2 Replacing the Display..................................................................................2-19
2.3.3 Replacing the Touch Panel..........................................................................2-20
2.4 Replacing the Weighing Unit ........................................................................ 2-21
2.5 Replacing the Numerical Keypad Cover (Optional) .................................... 2-23
2.6 Wireless LAN kit overseas edition expansion (Optional) ........................... 2-24

Introduction
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2.7 Curling inward label correspondence (Optional) ........................................ 2-26
Chapter 3 Electric Components ............................................................................ 3-1
3.1 PCB Configuration of the Electric Part .......................................................... 3-1
3.1.1 Main Board.....................................................................................................3-1
3.1.2 Key Control Board..........................................................................................3-4
3.1.3 Scale Board....................................................................................................3-5
Chapter 4 Setup Mode....................................................................................... 4-1
4.1 Startup .......................................................................................................... 4-1
4.2 MACHINE NO. SETTING .............................................................................. 4-3
4.2.1 MACHINE No. (BASIC).............................................................................4-3
4.2.2 MACHINE No. (IPADDR.)........................................................................4-4
4.2.3 MACHINE No. (PC COM).........................................................................4-5
4.2.4 MACHINE No. (WiFi)................................................................................4-6
4.2.5 MACHINE No. (GLOBAL SV.) ..................................................................4-7
4.2.6 MACHINE No. (SYNC.) ............................................................................4-8
4.2.7 MACHINE No. (OUTSIDE PRINTER)......................................................4-9
4.3 PASSWORD ............................................................................................... 4-10
4.3.1 PASSWORD (OPERATE).......................................................................4-10
4.4 KEY LOCK .................................................................................................. 4-11
4.4.1 KEY LOCK (DISPLAY KEY) ...................................................................4-11
4.4.2 KEY LOCK (FUNCTION KEY)................................................................4-12
4.4.3 KEY LOCK (STROKE KEY) ...................................................................4-13
4.5 DATA STORAGE ........................................................................................ 4-14
4.5.1 DATASTORAGE (TOTALADD.) ............................................................4-14
4.5.2 DATA STORAGE (TOTAL PROC.) .........................................................4-15
4.5.3 DATASTORAGE (TRANSACTION).......................................................4-16
4.5.4 DATASTORAGE (STORAGE) ...............................................................4-17
4.6 PLU OVERWRITE ....................................................................................... 4-18
4.7 PLU INITIAL DATA ..................................................................................... 4-19
4.7.1 PLU INITIAL DATA (SALE1)...................................................................4-19
4.7.2 PLU INITIAL DATA (MSG.)......................................................................4-20
4.7.3 PLU INITIAL DATA (IMAGE)...................................................................4-21
4.7.4 PLU INITIAL DATA (PRINT)....................................................................4-22
4.7.5 PLU INITIAL DATA (DATE).....................................................................4-23
4.7.6 PLU INITIAL DATA (CODE)....................................................................4-24
4.7.7 PLU INITIAL DATA (WRAP)....................................................................4-25
4.8 PLU UPDATE .............................................................................................. 4-26
4.9 LABEL COMB ............................................................................................. 4-27
4.9.1 LABEL COMB.（BASIC)..........................................................................4-28
4.9.2 LABEL COMB.（LABEL)..........................................................................4-29
4.9.3 LABEL COMB.（UPPER FIX)..................................................................4-31
4.9.4 LABEL COMB. / DETAIL.........................................................................4-32
4.10 LABEL FORMAT ........................................................................................ 4-33
4.10.1 LABEL FORMAT / PRINT CONTROL ....................................................4-34
4.10.2 LABEL FORMAT / DETAIL (BASIC) .......................................................4-35
4.10.3 LABEL FORMAT / DETAIL (UNIT)..........................................................4-37
4.10.4 LABEL FORMAT / DETAIL (PREVIEW) .................................................4-39
4.11 BARCODE .................................................................................................. 4-40
4.11.1 BARCODE (POS FLAG).........................................................................4-40
4.11.2 BARCODE(POS CODE).........................................................................4-41
4.11.3 BARCODE (ITEM CODE).......................................................................4-42

Introduction
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4.12 CUSTOM BARCODE .................................................................................. 4-43
4.12.1 CUSTOM BARCODE (BASIC)...............................................................4-44
4.12.2 CUSTOM BARCODE (PREVIEW).........................................................4-46
4.13 MENU TITLE ............................................................................................... 4-47
4.13.1 MENU TITLE (OPERATE)......................................................................4-47
4.14 OPERATION SETTING ............................................................................... 4-48
4.14.1 OPERATION SETTING (CALL1)............................................................4-48
4.14.2 OPERATION SETTING (CALL2)............................................................4-49
4.14.3 OPERATION SETTING (PROD.) ...........................................................4-50
4.14.4 OPERATION SETTING (PRINT.) ...........................................................4-51
4.15 ERROR PROCESS ..................................................................................... 4-52
4.15.1 ERROR PROCESS (ISSUE)..................................................................4-52
4.15.2 ERROR PROCESS (CALL)....................................................................4-53
4.15.3 ERROR PROCESS (COMMON)............................................................4-54
4.16 ERROR LOG ............................................................................................... 4-55
4.16.1 ERROR LOG (DISPLAY)........................................................................4-55
4.17 TRACE. ....................................................................................................... 4-56
4.18 DUAL CURRENCY ..................................................................................... 4-57
4.19 PRICE ROUNDING ..................................................................................... 4-58
4.20 FREQUENT SHOPPER ............................................................................... 4-59
4.21 STANDBY MODE ........................................................................................ 4-60
4.22 COUNTRY ................................................................................................... 4-61
4.22.1 COUNTRY / DETAIL (CURRENCY).......................................................4-62
4.22.2 COUNTRY / DETAIL (WEIGHT).............................................................4-63
4.22.3 COUNTRY / DETAIL (DATE)..................................................................4-64
4.23 FILE SAVE /LOAD ...................................................................................... 4-65
4.23.1 FILE SAVE/LOAD (USB>SCALE)..........................................................4-65
4.23.2 FILE SAVE/LOAD (SCALE>USB)..........................................................4-67
4.23.3 FILE SAVE/LOAD (USB DATA DEL.).....................................................4-69
4.23.4 FILE SAVE/LOAD (SCALE INIT.) ...........................................................4-71
4.23.5 FILE SAVE/LOAD / DETAIL....................................................................4-72
Chapter 5 Adjust Mode ..................................................................................... 5-1
5.1 Startup .......................................................................................................... 5-1
5.2 DATE TIME ................................................................................................... 5-3
5.3 TOUCH SCREEN .......................................................................................... 5-5
5.4 DISPLAY CHECK ......................................................................................... 5-6
5.5 SOUND ......................................................................................................... 5-7
5.6 KEY CHECK ................................................................................................. 5-8
5.7 FIRMWARE DETAILS ................................................................................... 5-9
5.8 MEMORY CLEAR ....................................................................................... 5-10
5.9 PRINTER ..................................................................................................... 5-12
5.9.1 PRINTER (HEAD)...................................................................................5-12
5.9.2 PRINTER (PEEL SENSOR) ...................................................................5-14
5.9.3 PRINTER (LABEL TYPE) .......................................................................5-15
5.9.4 PRINTER (LABEL FEED).......................................................................5-16
5.10 CALIBRATION ............................................................................................ 5-18
5.11 MACHINE TYPE.......................................................................................... 5-19
5.11.1 MACHINE TYPE / DETAIL......................................................................5-20
5.12 DOWNLOAD ............................................................................................... 5-22
5.12.1 DOWNLOAD (MAIN) ..............................................................................5-22

Introduction
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5.12.2 DOWNLOAD (SUB APP.) .......................................................................5-23
5.12.3 DOWNLOAD (SUB BOOT).....................................................................5-24
5.13 OPTION CHECK ......................................................................................... 5-25
5.13.1 OPTION CHECK (SCANNER) ...............................................................5-25
5.13.2 OPTION CHECK(USB)...........................................................................5-26
5.13.3 OPTION CHECK (DEVICE)....................................................................5-27
5.14 DISPLAY CAPTURE ................................................................................... 5-28
5.15 GRAVITY..................................................................................................... 5-29
Chapter 6 Trouble shooting .............................................................................. 6-1
6.1 Operation as IP (scale and printer) ............................................................. 6-1
6.2 Error Message .............................................................................................. 6-2
6.3 System Error ................................................................................................ 6-3
6.3.1 System-related Error (No. 100s)...............................................................6-3
6.3.2 Memory-related Error (No. 200s)............................................................6-14
6.3.3 Precheck-related Error (No. 300s)..........................................................6-44
6.3.4 Wrapper-related Error (No. 400s)...........................................................6-80
6.3.5 Applicator-related Error (No. 600s).......................................................6-154
6.3.6 Printer-related Error (No. 700s to 900s, 1300s, 1500s, 1600s, 1800s)6-174
6.3.7 Detector-related Error (No. 1500s).......................................................6-188
6.3.8 Scale-related Error (No. 1600s)............................................................6-201
6.3.9 Dialog Selection-related Error (No. 1800s) ..........................................6-205
Chapter 7 Appendix ............................................................................................. 1
7.1 Operation Sequence ........................................................................................1
7.1.1 At Start-up....................................................................................................1
7.1.2 When Issuing Labels....................................................................................4
7.2 Wiring Diagrams ..............................................................................................9

Chapter 1 Overview
1-1
Chapter 1 Overview
1.1 Specifications
Items
Descriptions
Product name
IP-AI
Product classification
Weight price labeler
Use conditions
Temperature 0°C to 40°C, Humidity 20% to 85% (Non condensing)
*The printable environment depends on the label specifications.
Installation status
Installation on an IP stand or a work table
Option
Name file stand
Numerical keypad cover
I2NET expansion board
Wireless LAN (simultaneously supporting WM-AI)
Protective sheet for panel
SD card theft prevention cover
◊The following items are reused from IP-UNI.
Wand scanner (DENSO HC56, GT-10B)
Wand scanner stand / holder
Inside winding
RS232 expansion board
*No PP interlocking.
External dimensions
Main unit 302(W) × 370(D) × 673(H) max.
Weighing unit 300(W) × 270(D) × 88(H) max.
Weight
Main unit 19kg max.
Weighing unit 6kg max.
Power supply
100 V ～ 240 V AC ±10% 50/60Hz
*No service outlet
Exterior
Printer body Grain finish (to prevent label from sticking)
Bottom part Metal coating
Drip resistance
Simple drip-proof structure (Water should not come into contact with
electric components when the vertical drop test is performed.)
Mechanism
Angle adjustment type (Angle: Front side -5° to back side 40°)
*Based on the upright position of the display part
Display
12.1-inch TFT color LCD with LED backlight
SVGA (800600)
Used keys
Resistance film type analog touch panel
Keystroke (24 keys max.)
Key dimensions
Touch panel: approx. 248mm × 187mm (effective area)
Keystroke Single: approx. 18 × 18
Double: approx. 18 × 37
Printing method
Direct thermal method
Thermal head
3-inch (960 dots and 12 dots/mm) thermal head
Printing speed
150 mm / sec. max. (Target value)
*The printing speed can be switched depending on the label sensitivity.
Effective printing size
Width 78mm
Label replacing
method
Front-loading

Chapter 1 Overview
1-2
Items
Descriptions
Label roll diameter
Paper pipe inner diameter φ76mm
Maximum outer diameter φ224mm
Label storage
capacity
5000 labels (42mm, 2.5mm gap)
Label size
Label width 20mm to 80mm
Label length 20mm to 150mm
*Label backing paper width 82mm max.
Issuing method
Switchable between label peeling-off and continuous label printing.
Back-feed issue possible.
Label winding
direction
Outside winding
Label shape
Circular and oval labels can be handled.
Barcode
(Symbol)
1-dimensional: JAN, ITF, CODE128, EAN128
2-dimensional: QR (1:1 feeding, Label type: Ricoh 150LA-1)
Vertical bar only (The ladder bar is not supported.)
Recommended label
OSAKA SELING V8NS
Ricoh 150LA-1
Printing accuracy
Width direction :0.5mm
Print start position :0.5mm
Print length :Less than 60mm of label height:  1mm or less
60mm or above of label height: 2mm or less
Weighing type
•6kg: 0 to 3kg/1g, 3 to 6kg/2g Multiple interval
•15kg: 0 to 6kg/2g, 6 to 15kg/5g Multiple 2g Multiple interval
•30lb 0～15lb／0.005lb 15～30lb／0.01 lb
Weighing accuracy
1/3000 (Accuracy class: Class III)
OS specification
Linux
Standard Input/output
Ethernet (10/100base-TX) :1 ch
RS-232C :4 ch (1ch is used only for scanner.)
SDCard :1 ch
UDF support
UD font mounted
MORISAWA UD Shin Go
(Style: M, DB, B Character collection: Adobe-Japan1-4)
Power saving mode
The machine shifts to a power saving mode when no operation is
performed for a fixed time.
Specification type
Standard specifications (Store offline)
Higher-level
communication
Corresponding to SLP-5.
Lifetime
Duration of service: 5 years Lifetime: 233.6km
Assumption: 3000 labels/day, 350 days/year, label height 42mm, label
gap 2.5mm, 12 hours/day
4,200 hours/year, 21,000 hours for 5 years
3,000 labels  350 days = 1,050,000 labels/year
1,050,000 labels  5 years = 5,250,000 labels
5,250,000 labels  (42mm + 2.5mm) = 2,336,000 mm
Consumable parts
Thermal head, print roller
Cleaning
Parts to be cleaned (A cleaning manual and a cleaning kit are provided.)
Thermal head
Label path

Chapter 1 Overview
1-3
Items
Descriptions
Safety
Ishida product safety standards
Signal word standards
CE marking · UL · cUL
Standards
Compliant with Ishida product standards and Ishida sanitation standards
Japanese Measurement Act
NTEP (USA) · OIML(Europe)

Chapter 1 Overview
1-4
1.2 Features
The display has been changed to 12.1 inches and the thermal head to 12 dots/mm based on IP-UNI.
・The machine has a built-in wireless LAN and a built-in M2M board (optional), which make it easier to
upgrade the remote maintenance program.
High-accuracy printing
contributes to creating stores
that are safe and secure for
consumers.
The larger display allows
elderly operators to easily see
and contributes to prevention
of operation mistakes.

Chapter 1 Overview
1-5
1.3 Name of Each Part
Front view
NOTE:
The label cassette is called the label printer in the operation manual. The label cassette of the machine is
not replaceable.
Rear view
Fuse for machine
Power supply code
Grounding
terminal
Touch panel
Keypad
Label outlet
Power switch
Level adjustable leg
Label cassette
(“Label printer” in the operation manual)
Scale unit
Level

Chapter 1 Overview
1-6
1.4 Dimensions
The following drawing shows the dimensions. Make sure to secure a carry-in route and space required for
setup and maintenance.
Unit: mm

Chapter 1 Overview
1-7
1.5 Items Required for Installation
No.
Description
Check
1
Balance weight (6kg, equivalent to M1 class)
□
2
USB memory
(that stores data of the user)
□
3
Labels
□
4
Phillips head screwdriver
□

Chapter 1 Overview
1-8
1.6 Installation Space
 Secure sufficient working space on the left and right side of the machine.
Space for
label replacement
300 mm

Chapter 1 Overview
1-9
1.7 Power Supply
 This machine requires single-phase 100VAC
power supply with 4A capacity. The shape
and rating of the power plug are illustrated.
Prepare an outlet which conforms to the
standards.
 Noise or a voltage drop in the power supply
will cause a malfunction. Make sure to install
a dedicated power supply.
 Perform class D grounding (former class 3
grounding) or higher to prevent electric
shocks and malfunctions.
 Noise or a voltage drop in the power supply
will cause a malfunction. Make sure to install
a dedicated power supply.
Select a breaker for the building which achieves protection
coordination. This machine uses a motor to perform switching
operation, which causes high-frequency components and leakage
current to increase compared to general commercial power supply. As
there is harmonic leakage current, always install a breaker
corresponding to harmonic current.
All electric work must be performed by a qualified electrical engineer.
To prevent accidents due to electric shock, always ground the machine.
100VAC outlet
Power plug
Screw type
grounding terminal

Chapter 1 Overview
1-10
1.8 Carry-in and Installation
1.8.1 Installation Procedure Check Sheet
Step
Description
Check
1
Carry in IP-AI. (Total weight 25kg)
・Confirm the installation place.
□
2
Connect the cable of the weighing unit to the main unit.
□
3
* Make an adjustment so that the bubble is located at the center of the level
gauge.
□
4
When connecting the PP-AI, connect the provided grounding terminal to the
PP-AI.
When connecting other machines, connect them according to the following:
Other machine of master-slave system .............. LAN
Optional printer (PP-AI) ............... ...................... USB
Journal printer ............................ ........................ RS-232C
□
5
・Connect the power plug to the single-phase 100VAC outlet.
□
6
・Set the labels.
Refer to Chapter 1 "Label setting" in the operation manual.
□
Be sure to pull out the power plug from the outlet when connecting
machines.

Chapter 1 Overview
1-11
1.9 Setup
1.9.1 Requirements for Setup
 USB flash memory (that stores data of the user)
 Balance weight (6kg, equivalent to M1 class)
1.9.2 Setup Procedure
 Perform a setup operation in the [Setup Mode] and the [Adjust Mode] on the maintenance screen whose
authority is controlled with login.
Refer to Chapter 4 Setup Mode and Chapter 5 Adjust Mode for each operation.
• The following three adjustments can be made in the Setup Mode on the normal screen.
1) Items required for adjusting
 Memory initialization (Adjust Mode)
 Printer (Label adjustment) (Adjust Mode)
 Production processing (Setup Mode)
 Issuing pattern (Setup Mode)
 Formatting (Setup Mode)
 Error processing (Setup Mode)
 Total amount (Setup Mode)
 POS (Setup Mode)
2) Downloading data of the user
・To use the USB flash memory that stores data of the user, select [FILE SAVE/LOAD] in the Setup
Mode for maintenance and download to this machine on the [USB > SCALE] tab page.
File input/output screen
To logout (return to the first screen), do not enter any value or enter "0", and press the [Login] button.

Chapter 1 Overview
1-12
Recommended product (USB memory stick)
Product No.：0001495390**
Product Name: Hagiwara, USB, 1G
NOTE:
Please note that the recommended USB memory is subject to change without notice.
3) Items required for checking (Setup Mode)
 Password
 Item data auto update
 Key lock
 Item initial value settings
 Individual identification
 File input/output
 Function key
 Total addition
 Pack date/Expiry date
 Function key
 Machine/department number (Set this according to the specifications.)

Chapter 1 Overview
1-13
1.9.3 Operation Checks
■ Weighing check
Place a balance weight (6 kg, equivalent to M1 class) on the weighing platter and confirm that the
displayed weight is within 6,000 g  1 scale unit (2 g).
■ Four-corner check
Place a weight (approximately 3kg but not heavier) on the center and four corners of the weighing platter,
and conform that the difference between the center and four corners is within 1 scale unit (1 kg).
■ Label printing check
Check the print on labels that are used by the users.
(Confirm that the following data are correct: date, weight, calculation processing of weight and unit price
and price display.)
1.9.4 Operation Explanation
Explain the operation method and precautions to the user based on the operation manual. Confirm that the
user fully understands.
1.9.5 Issuing a Warranty
Fill in necessary items in the warranty and give it to the user.