Avery Weigh-Tronix ZM510 User manual

AWT35-501664
Issue AB
ZM510
Indicator
Service Manual
original instructions
AMERICAS
CONFIDENTIAL

ZM510_US_s_en_501664.book
Avery Weigh-Tronix is a trademark of the Illinois Tool Works group of companies whose ultimate parent company is
Illinois Tool Works Inc (“Illinois Tool Works”). Copyright © 2017 Illinois Tool Works. All rights reserved.
No part of this publication may be reproduced by making a facsimile copy, by the making of a copy in three dimensions of a two-dimensional
work and the making of a copy in two dimensions of a three-dimensional work, stored in any medium by electronic means, or transmitted in
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copyright owner, under license, or as permitted by law.
This publication was correct at the time of going to print, however Avery Weigh-Tronix reserves the right to alter without notice the
specification, design, price or conditions of supply of any product or service at any time.

ZM510 Indicator Service Manual 3
Table of Contents
page
Manual revision history .............................................................................................................................7
Chapter 1 General information and warnings .........................................................................................9
About this manual ..............................................................................................................9
Text conventions .........................................................................................................9
Special messages .......................................................................................................9
Installation ........................................................................................................................10
Torque specifications ................................................................................................10
Proper grounding of cables .......................................................................................10
Safe handling of equipment with batteries ................................................................11
Wet conditions ...........................................................................................................11
Panel mount scale interface cable installation ..........................................................11
Routine maintenance .......................................................................................................12
Cleaning the machine ......................................................................................................13
Training ............................................................................................................................13
Sharp objects ...................................................................................................................13
FCC and EMC declarations of compliance ......................................................................13
Chapter 2 Introduction ............................................................................................................................14
Front Panel Keys .............................................................................................................15
Display .............................................................................................................................16
Chapter 3 Introduction to the menus .....................................................................................................17
Menu Navigation ..............................................................................................................17
Exiting a menu .................................................................................................................18
Chapter 4 User level menu ......................................................................................................................19
User menu .......................................................................................................................19
About menu ......................................................................................................................20
Audit menu .......................................................................................................................22
Chapter 5 Diagnostics menu ..................................................................................................................23
Scale ................................................................................................................................23
Cur.Zero ...........................................................................................................................23
Display .............................................................................................................................24
Buttons .............................................................................................................................24
Ports .................................................................................................................................24
Inputs ...............................................................................................................................24
Outputs ............................................................................................................................25
Logs .................................................................................................................................25
Options .............................................................................................................................26
BSQ .................................................................................................................................26
DigJbox ............................................................................................................................26
Chapter 6 ADMIN Menu ...........................................................................................................................27
Calibrate ...........................................................................................................................29
Zero procedure ..........................................................................................................29
Span procedure .........................................................................................................30
Linearity (Linear) procedure ......................................................................................31
Input procedure .........................................................................................................31
Gravity procedure ......................................................................................................31
Display procedure .....................................................................................................32
Cal Unit procedure ....................................................................................................32

4 ZM510 Indicator Service Manual
Print procedure .......................................................................................................... 32
Scale menu ...................................................................................................................... 32
Capacty ..................................................................................................................... 33
Dvision ..................................................................................................................... 33
Units ..........................................................................................................................33
Stable ........................................................................................................................34
AZT ...........................................................................................................................34
Filter .......................................................................................................................... 34
Ranges ...................................................................................................................... 36
2,3 Range .................................................................................................................. 36
Type ..........................................................................................................................37
Roc ............................................................................................................................37
DigJbox ..................................................................................................................... 38
Traffic ........................................................................................................................38
System menu ................................................................................................................... 38
Site ............................................................................................................................ 39
Display ...................................................................................................................... 39
Buttons ...................................................................................................................... 40
D-Vals ....................................................................................................................... 40
Tare ...........................................................................................................................42
Config ........................................................................................................................ 43
Archive ...................................................................................................................... 43
Serial .........................................................................................................................43
Update ....................................................................................................................... 44
Password .................................................................................................................. 44
Z-Lock ....................................................................................................................... 44
Beeper ....................................................................................................................... 44
Num Scl ..................................................................................................................... 45
Ports menu ...................................................................................................................... 45
Serial .........................................................................................................................45
Protcl .........................................................................................................................48
P.F. Edit .................................................................................................................... 50
PLC ...........................................................................................................................51
Printer ........................................................................................................................52
File ............................................................................................................................ 53
Options ...................................................................................................................... 54
Chapter 7 Communication port protocols ............................................................................................ 57
SMA Protocol ...................................................................................................................57
Level 1 and 2 Commands ........................................................................................ 57
Standard Scale Response Message ......................................................................... 58
Unrecognized Command Response ......................................................................... 58
About Command Response ...................................................................................... 58
Scale Information Command Response ................................................................... 59
Avery Weigh-Tronix Extended SMA Commands ...................................................... 60
ENQ & B-Cast commands ............................................................................................... 62
NCI commands ................................................................................................................ 63
PLC Configuration information ........................................................................................ 64
ModBus/TCP ............................................................................................................. 64
Ethernet/IP Implicit Messaging: ................................................................................. 65
Ethernet/IP Explicit Messaging: ................................................................................ 66
Chapter 8 Option cards ........................................................................................................................... 67
Switch S1 settings ........................................................................................................... 69
Analog output card .......................................................................................................... 70
Current Loop/RS485/RS422 card .................................................................................... 71
USB Device option card .................................................................................................. 72

ZM510 Indicator Service Manual 5
DeviceNetTM option card ................................................................................................73
Software controlled baud rate ...................................................................................74
Profibus© .........................................................................................................................74
S2 switch settings: .....................................................................................................75
Wireless Ethernet communication (802.11g) card ...........................................................76
Internal 120 VAC relay card .............................................................................................77
Specifications ............................................................................................................77
Installing the option card ...........................................................................................78
Analog Scale Input Option with 5VDC Excitation .............................................................79
Analog Scale Input Option with 10 VDC Exit. and STVS .................................................80
External I/O Interface card ...............................................................................................81
AC input, 4 Inputs (120-240VAC) card ............................................................................82
DC input, 4 inputs(4-30VDC) card ...................................................................................83
AC output, 4 relays (20-240VAC) card ............................................................................84
DC output, 4 relays (3-60VDC) card ................................................................................85
STVS (Severe Transient Voltage Suppressor) card ........................................................86
Chapter 9 Printed reports .......................................................................................................................87
Configuration report .........................................................................................................87
Calibration report .............................................................................................................87
Audit report ......................................................................................................................88
Chapter 10 Print formatting ....................................................................................................................89
Print Format Editor ...........................................................................................................89
Editing an existing print string ..........................................................................................90
Inserting characters ...................................................................................................91
Deleting characters ...................................................................................................92
Inserting tokens, etc. ........................................................................................................94
Other scale tokens ...........................................................................................................96
Transmitting leading zeros ...............................................................................................97
Print format errors ............................................................................................................98
Chapter 11 Print tokens, parameters and default print formats ..........................................................99
Notes on width syntax ......................................................................................................99
Explanation of width syntax for WEIGHT (integers) ..................................................99
Explanation of width syntax for WEIGHT (strings) ....................................................99
Explanation of width syntax for UNITS OF MEASURE (strings) ...............................99
Firmware tokens ............................................................................................................100
Application Tokens .........................................................................................................106
Additional token tables ...................................................................................................107
Network tokens ..............................................................................................................108
ASCII characters (UNI-code UTF-8) ..............................................................................111
Control codes .................................................................................................................112
Chapter 12 ZM510 Menus ......................................................................................................................113
Chapter 13 Technical illustrations .......................................................................................................115
Exploded drawing ..........................................................................................................115
Parts Kits ........................................................................................................................116
Panel mount exploded drawing ......................................................................................117
Panel Mount kits ....................................................................................................................................117
Panel mount assembly ...................................................................................................118
System block diagram ....................................................................................................119
ZM Remote Inputs and Outputs, Opto-22 Module Application Notes ............................120
I/O interfaces ...........................................................................................................120
Inputs .......................................................................................................................120
Outputs ....................................................................................................................121
Diagnostics ..............................................................................................................122

6 ZM510 Indicator Service Manual
External Opto I/O Cards ................................................................................................ 125
Index ....................................................................................................................................................... 127

ZM510 Indicator Service Manual 7
Manual revision history
Current
Issue Date Created Details of Changes
AA May 2017 New manual
AB June 2017 Correction on page 81.

8 ZM510 Indicator Service Manual

ZM510 Indicator Service Manual 9
1.1 About this manual
1 General information and warnings
1.1 About this manual
This manual is dividedinto chapters by the chapter number and the large text at the top
of a page. Subsections are labeled using the 1.1 and 1.1.1 convention. The names of
the chapter and the next subsection level appear at the top of alternating pages of the
manual to remind you of where you are in the manual. The manual name and page
numbers appear at the bottom of the pages.
1.1.1 Text conventions
Key names are shown in bold and reflect the case of the key being described. If a key
has dual functions,the function is shown first followed by the keyname in parentheses
and in bold, such as in these examples: F1, SELECT, PRINT, etc.
Displayed messages appear in bold italic type and reflect the case of the displayed
message.
1.1.2 Special messages
Examples of special messages you will see in this manual are defined below. The
heading words have specific meanings to alert you to additional information or the
relative level of hazard.
ELECTRICAL WARNING!
THIS IS AN ELECTRICAL WARNING SYMBOL.
ELECTRICAL WARNINGS MEAN THAT FAILURE TO FOLLOW
SPECIFIC PRACTICES OR PROCEDURES MAY RESULT IN
ELECTROCUTION, ARC BURNS, EXPLOSIONS OR OTHER HAZARDS
THAT MAY CAUSE INJURY OR DEATH.
WARNING!
This is a Warning symbol.
Warnings mean that failure to follow specific practices and procedures may
have major consequences such as injury or death.
CAUTION!
This is a Caution symbol.
Cautions give information about procedures that, if not observed, could result
in damage to equipment or corruption to and loss of data.
NOTE: This is a Note symbol. Notes give additional and important information, hints
and tips that help you to use your product.

10 ZM510 Indicator Service Manual
1 General information and warnings
1.2 Installation
1.2.1 Torque specifications
There are four sizes of strain reliefs exiting the indicator: PG11, PG7, PG13.5 and NPT
3/4”. The torque specifications for the locknuts which hold the strain reliefs to the
indicator housing and the specs for the dome nuts which seal the cable that passes
through the strain relief are shown in the table below.
The vent in the back cover should be torqued between 5.3 and 7.1 lb-in (0.6-0.8 N-m).
1.2.2 Proper grounding of cables
On the stainless steel desktop models, cable shield wires should be grounded directly
tothestuds providedat the bottomoftheenclosure,closeto thestrainrelief entrypoint,
with wire lengths at a minimum. On the aluminum and panel mount models the shield
wires should be connected to the SHLD connection on the corresponding terminal
block connectors.
NO USER SERVICEABLE PARTS. REFER TO QUALIFIED SERVICE
PERSONNEL FOR SERVICE.
CAUTION: The acorn nuts holding the back plate of the indicator in place must
each be tightened, in multiple passes, in the following pattern to a final torque
of 0.68 N-m (approximately 6 in-lbs) to ensure proper gasket sealing.
1
2
3
4
5
6
7
89
10
11
12
13
14
Indicator back
plate
3/4” NPT
Strain Relief
PG13.5 Strain
Relief
PG11 Strain
Relief
PG7 Strain
Relief
Dome Nut 44.2 lb-in
5 N-m 22.1 lb-in 2.5 N-m 22.1 lb-in 2.5 N-m 8.9 lb-in 1.0 N-m
Lock Nut 66.4 lb-in
7.5 N-m 33.2 lb-in 3.75 N-m 33.2 lb-in 3.75 N-m 13.3 lb-in 1.5 N-m