Avery Weigh-Tronix PC-220 User manual

PC-220 Counting Scale
Service Manual

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Table of Contents
Removing the Covers ------------------------------------------------------------------ 5
Status Display ---------------------------------------------------------------------------- 6
Error Messages -------------------------------------------------------------------------- 7
Configuring the Scale ------------------------------------------------------------------ 8
Management Mode ----------------------------------------------------------------- 8
Restricted Service Access ------------------------------------------------------- 8
Full Service Access ---------------------------------------------------------------- 9
Verification Mode ------------------------------------------------------------------- 9
Exiting from Full or Restricted Service Access ----------------------------- 9
Navigating the Service Mode ------------------------------------------------------- 10
Product Configuration Branches -------------------------------------------------- 11
Branch 0 - Edit Counter -------------------------------------------------------- 11
Branch 5 - Typical Configurations -------------------------------------------- 11
Branch 6 - Weighing Functionality ------------------------------------------- 11
Branch 7 - Weighing Limits ---------------------------------------------------- 13
Branch 08 - Gravity Compensation ------------------------------------------ 13
Branch 09 - Weight Display ---------------------------------------------------- 14
Branch 19 - Beeper Functions ------------------------------------------------ 14
Branch 20 - Power Saving ----------------------------------------------------- 14
Branch 29 - Key Press Duration ---------------------------------------------- 15
Branch 60 - Tares ---------------------------------------------------------------- 15
Branch 61 - Application Configuration -------------------------------------- 15
Branch 100 - PLUs --------------------------------------------------------------- 16
Calibration ------------------------------------------------------------------------------- 17
Simple Calibration ---------------------------------------------------------------- 17
Full Service Calibration --------------------------------------------------------- 17
Aborting Calibration -------------------------------------------------------------- 18
30kg/60lb Scales ---------------------------------------------------------------------- 18
Replacing Base Covers -------------------------------------------------------------- 18
Illustrated Parts List ------------------------------------------------------------------- 19
Wiring Diagram ------------------------------------------------------------------------ 20
Pages are numbered consecutively beginning with the cover page.

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Removing the Covers
1. Disconnect the power supply from the scale.
2. Remove the scale platter.
3. Break the tamper seal.
4. Remove screw A and remove the expansion board cover.
5. Remove the feet (and the springs if the scale is a 30kg machine).
6. Remove screw B at the front edge of the scale.
7. Lever the clips holding the cover using a flat-blade screwdriver.
When replacing the cover, if
either of the clips are dam-
aged an M6 or self-tapping
screw (C) can be used to hold
the cover in place.

6
Status Display
The status display shows some basic information about the scale. To view
this information, press the ON/OFF key twice. A sample display is shown
below as well as a reference table.
Top Row Middle Row Bottom Row
0 Boot block product code Boot block version number
1 Application block Application block version
product code number
2 Configuration block Configuration block
product code version number
3 Product configuration Product configuration
checksum status: edit counter
0 = OK
1 = Checksum failed
4 Mains/battery voltage Blank
5 Secondary calibration Blank
counter
6 Cause of last reset: Blank
0 = Power down
1 = Watchdog
2 = Clock monitor
If you need to contact your authorized Weigh-Tronix distributor, make a
note of all these settings.
= ON/OFF key

7
Error Messages
E5 Disconnect then reconnect the power supply.
E10 Battery failure - replace the batteries (do not use NiCad batteries).
E11 Power supply voltage too high. Make sure the correct power supply
is being used.
E15 Disconnect then reconnect the power supply.
E19 Software download tool error. Try downloading the application again.
E20 Disconnect then reconnect the power supply. If the error reappears,
you will need to replace the load cell.
E21 This could be caused by excessive vibration or an incorrect service
calibration. Either adjust the filters or recalibrate the scale.
E30 Management/Service mode not exited correctly. Re-enter service
mode, select the value to be changed, change the value and go to
the next branch or sub-branch to accept the change.
E35 An invalid configuration for the scale has been given in branch 5.
Re-enter the configurations.
E36 An invalid capacity for the scale has been given in branch 5. Re-
enter the configurations.
E40 The weight used for user calibration is unsteady. Recalibrate the
scale.
E41 An incorrect weight is being used for user calibration. Use the
correct weights.
E42 User calibration is not available for this scale.
E100 Invalid PLU contents. Reprogram the PLU.
E101 Transaction failed.
E102 Transaction failed.
E103 Tare failed. Reprogram the tare.
E110 The counting piece weight is greater than 10% of the capacity of the
scale.
E151 A change to the configuration has failed. Reprogram the configura-
tion.
E152 The user does not have access to this item (in management mode).
Temporary
error
Weight
unsteady
Balance
failed
Under
range
Over
range

8
Configuring the Scale
There are 3 ways to configure the scale:
This mode allows you to configure a few branches of the scale. Because
the configurations can be different for each scale, refer to the User’s
Manual for details on the branches available.
To enter the management mode, press the ON/OFF key, then key in 6231
on the numeric keypad.
To exit management mode, press the ON/OFF key, then the Zero key.
This mode allows you to see all of the scale’s configuration. You will not be
able to alter the branches that are marked as Full service access only. If
you attempt to change these configurations you will see an error message
(E152).
To enter restricted service access, press the ON/OFF key, then the Tare
key, Zero key, Tare key, Zero key, Tare key, Zero key. The scale is now
in verification mode. (see Verification Mode)
Management Mode
Restricted Service
Access

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Full Service Access This will give full access to the scale’s configuration.
1. Unplug the scale from the power supply.
2. Break the security seal and remove the blanking plate.
3. Plug the service tool (PN 18165-140) into the side of the scale.
4. Replace the scale platter and reconnect the power supply. The scale
will now be in verification mode. (see Verification Mode)
Verification mode will display the weight to four decimal places, and zero
tracking will be disabled.
To go to the configuration menus, press the ON/OFF key, then the left
arrow key. See note at left.
If you need to return to verification mode at any time, press the ON/OFF
key, then the up arrow key. See note at left.
To exit, long press the ON/OFF key. The display will show E 5. You will
need to disconnect the power supply, remove the service tool if you are in
full service access, and reconnect the power supply.
Verification Mode
= Left arrow key
= Up arrow key
Exiting from Full
or Restricted Service
Access
If you do not exit service
mode correctly you will se an
E 30 error message.

10
Navigating the Service Mode
Each configuration setting consists of a value and a location. The location
consists of a Branch number and a Sub-branch number. See note at left.
For example shown at left:
Branch 5 = Weighing capacity
Sub-branch 05 = Primary
Capacity units value 129 = lb
Function Key
Go to next branch. Long press
Go to the next sub-branch. Short press
Go to the previous branch.* Long press
Go to the previous sub-branch.* Short press
Go to branch 00 Long press
Select value to be changed Short press
Change the value. (see note at left) Enter a value*
or
Short press
Increment the value X10. Long press
Exit service mode. Long press
If you are using the service tool,
disconnect the power supply and
remove the tool before repowering
the scale.
After changing a value, you
must go to the next branch or
sub-branch to accept the
change.
You MUST press the Clear
key to clear a value before
keying in a new one.

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Product Configuration Branches
For older application block
versions (0-5-0 or earlier)
some branches or sub-
branches are not available.
Branch 0 - Edit Counter Sub-branch Value
00 - default user mode This counter is automatically incremented
whenever the product configuration has been
altered.
Full service access only.
Sub-branch Numbers
Capacity 00 01 02 03 04 05 06 07 08 09 10 11 12
15lb x 0.0005 150000 0 0 2 4 129 0 0 0 0 0 0 100
30lb x 0.001 30000 0 0 0 3 129 0 0 0 0 0 0 200
60lb x 0.002 60000 0 0 1 3 129 0 0 0 0 0 0 200
6kg x 0.2g 600000 0 0 1 4 1 0 0 0 0 0 0 200
15kg x 0.5g 150000 0 0 2 4 1 0 0 0 0 0 0 200
30kg x 1g 30000 0 0 0 3 1 0 0 0 0 0 0 200
Branch 5 -
Typical Configurations
If you enter an incorrect value
for these configurations, you
will see an E 30 or E 35 error.
Re-enter the correct values.
Branch 6 -
Weighing Functionality
Value
0 - Gross zero appears when the range is between
±0.25 divisions.
1 - Gross zero appears when the range is be-
tween ±0.5 divisions.
0 - Disabled.
1 - Enabled
0 - Disabled. No test performed.
1 - -5 to 15%
3 - -2 to 2%
Sub-branch
00 - Zero Indicator. This determines when the gross
zero indicator appears on the display.
01 - Zero tracking. This is used to account for minor
weight changes over time. For example when
weighing in dusty environments.
02 - Balance on power up. When powered up, the
scale determines if it is within its previous bal-
ance range. If it is, it looks at sub-branch 03. If it
is not, a balance failed indicator will appear. A
typical example of an error is if the scale is
powered up without the scale platform on the
scale.
Full service access only. Bold values are factory default settings.

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Value
0 - Disabled.
1 - Enabled
0 - Gross zero division
1 - Between 0 and 20 divisions
0 - Disabled
1 - Enabled
0 - 200 Primary capacity (%) multiplied by 2
Default is 4
For example: 200 = 100% 50 = 25%
0 - Default filter (3)
1-8 1 = Slight filter, 8 = Strong filter
Default is 4
0 - 200 Primary capacity (%) multiplied by 2
Default is 24
0 - 255 divisions
Default is 60
0 - disable alternate units
1 - USA decimal Pounds
2 - Grams
0 - ± 0.1 divisions
1 - ± 0.25 divisions
2 - ± 0.5 divisions
3 - ± 1 divisions
4 - ± 1.5 divisions
5 - ± 2 divisions
6 - ± 3 divisions
7 - ± 5 divisions
0 - Allow any tare increment
1 - Tare increment must be a multiple of the weight
increment
0 - Disable automatic re-tare
1-200 tare range (%) multiplied by 2
Default is 2
For example: 200 = 100% 50 = 25%
Sub-branch
03 - Automatic zero self balance. If enabled, the
scale will automatically perform a balance.
05 - Weight return to zero. When a weight has been
removed from the scale, this determines how
near to zero the scale must be before displaying
the zero indicator.
06 - Hysteresis. This is used to prevent the weight
display from flickering between the top of one
weight increment and the bottom of the next.
07 - Normal balance range. This is percentage of
the capacity that the zero can move away from
the power up balance due to zero tracking,
automatic or manual balance.
08 - Filters. If the scale is in an environment where
there is vibration, filters can be applied so that
the weight display remains steady. The stronger
the filter the longer the display will take to display
a weight.
09 - Minimum test weight for customer calibra-
tion. Not available.
10- Maximum correction from customer calibra-
tion.
11 - Alternate Units. This will convert the displayed
weight into the selected units.
12- Weight steady. The weight must remain within
the given ± range for a set amount of time before
the weight is displayed.
13 - Tare increment. This sets the tare value that
can be accepted by the scale. For example, on a
15kg x 5g scale, if the tare increment is set to 1,
then the tare weight must be a multiple of 5g. If
the tare weight is not a multiple, then the scale
will not accept the tare.
14 - Automatic re-tare. This sets the percentage of
a tare within which subsequent tares will also be
allowed without having to press the tare key.
This is generally used where there is minor
weight variation between containers. For ex-
ample, cardboard boxes.

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Branch 7 -
Weighing Limits
Value
0 - 65535 divisions
This is the minimum weight (shown on the
overlay) divided by the minimum weight incre-
ment (e).
0 - 65535 divisions
Sub-branch
00 - Minimum weight. This restricts the weight
display so that it remains blank until the minimum
weight has been exceeded.
01 - Under range limit. If the scale is set to display
negative values (Branch 9 sub-branch 00) the
weight display remains blank until the negative
weight has been exceeded.
Full service access only.
Branch 08 -
Gravity Compensation
Value
As published by the support office of your
national distributor.
Minimum value = 975,000
Maximum value = 985,000
You must enter a six digit value as the gravity
factors are automatically set to five decimal
places.
Sub-branch
00 - Calibration gravity factor. This is the gravity
factor of the location where the scale has been
calibrated.
01 - Site gravity factor. This is the gravity factor of
the location where the scale is to be used.
Full service access only.
If the scale is to be calibrated and used in the same gravity zone, then
both gravity factors should be set to 0.
If you intend to calibrate the scale and then send the scale to a different
gravity zone, you must enter the calibration and site gravity factors.
If you do not know the site gravity factor, you must enter the calibration
gravity factor and send a note with the scale stating that the site gravity
factor is to be entered and needs to be reverified and stamped before
being sold to the customer.
Once the calibration and site
gravity factors have been
entered, the scale may not
weigh correctly until the scale
is at the site.

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Branch 09 -
Weight Display
Value
0 - Negative weight display.
0 - Comma
1 - Decimal point
Sub-branch
00 - Blank net weight display. This sets the display
to either show a negative net weight or to blank
the display when a tare is created and then
removed from the scale.
01 - Weight decimal marker type.
Full service access only.
Branch 19 -
Weight Display
Value
0 - Disabled
1 - Enabled
0 - Disabled
1 - Enabled
0 - Disabled
1 - Enabled
0 - Disabled
1 - Enabled
0 - Quiet
1 - Loud
Sub-branch
00 - Beep when below zero.
01 - Keyboard beep.
02 - Target beep.
03 - Error beep.
04 - Beeper volume.
Branch 20-
Power Saving
Value
0 - Permanently off
1 - 5 seconds
2 - 1 minute
3 - 5 minutes
4 - Permanently on
0 - No sleep timeout
1 - 1 minute
2 - 5 minutes
3 - 30 minutes
Sub-branch
00 - Backlight timeout. This is the length of time
between the last scale activity and the backlight
being activated.
01 - Sleep timeout. This is the length of time between
the last scale activity and the scale going into
SLEEP mode.

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Branch 29-
Key Press Duration
Value
1 - 255 milliseconds X 10 (E.g. 200 = 2 sec.)
Default is 50
Sub-branch
00 - Long key press duration.
Branch 60- Tares
Value
0 - Manual balance disabled while any tare is active
1 - Manual balance clears the tare after a suc-
cessful balance.
Weight in grams/lb - depends on scale unit of measure
Weight in grams/lb - depends on scale unit of measure
0 - Disabled
1 - Enabled
0 - Disabled
1 - Enabled
0 - Disabled
1 - Enabled
0 - Disabled
1 - Enabled
Sub-branch
00 - Manual balance while tare is active.
01 - Minimum piece weight.
02 - Minimum sample size.
03 - Item count thousands separator.
04 - Keyboard entered (graduated) tare.
05 - Cumulative tare.
06 - Stored tare.
See also branch 6 sub-branch 13 - tare increment, and branch 6 sub-
branch 14 - automatic re-tare.
Branch 61- Application
Configuration
Value
0 - 655535 Value in grams or 0.001 lb
1 - 1 g or 0.001 lb
0 - 99 Disable manual resampling.
100 - 65535 Sampling when item count is
>= sample size. Item count must be
<= 100 to 65535% of the sample size
to automatically resample
Default is 200
Sub-branch
00 - Minimum Sample Weight
01 - Manual resample range
Full service access for all sub-branches.

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Branch 100 - PLUs
Value
0 - Write enabled
1 - Write protected
Weight in grams/lb - depends on scale unit of measure
Weight in grams/lb - depends on scale unit of measure
Sub-branch
00 - Write protect.
01 - Piece weight.
02 - Stored tare.
The branch number for a PLU = 100 plus the PLU number. For example:
PLU 5 = 105, PLU 19 = 119.
Sub-branch
02 - Auto resample range
03 - Count thousands separator
04 - Enable PLUs
05 - Piece Weight Units
06 - Piece Weight Decimal Places
Value
0 - 99 Disable auto resampling.
100 - 65535 Enable auto resampling when item
count is >= sample size.
Item count must be <= 100 to 65535%
of the sample size to automatically
resample.
0 - Disabled
1 - Enabled
0 - Disabled
1 - Enabled
0 - Calculate piece weight in grams
1 - Calculate piece weight in the current units
0. . 6 Number of decimal places
4 is default for Kg/g configurations
6 is default for Lb configurations

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Calibration
Follow these procedures to perform a simple, one weight calibration.
1. Press the On/Off key then press
the Clear key. . . Display shows CAL in top line with
weight displayed on middle line.
2. Place calibration weight on the
scale and press the Clear key. . . If the weight is acceptable and
stable, the display will show DONE
in the middle line for two seconds.
3. To exit the calibration mode,
press the On/Off key then press
the Zero key.
Full Service Calibration
Simple Calibration
You will only be allowed to perform a full calibration of the scale when
using full service access.
1. Unplug the scale from the power supply.
2. Break the tamper seal, remove the blanking plate and plug the service
tool into the side of the scale.
3. Replace the scale platform and reconnect the power supply.
4. Check that the gravity factors are correct.
5. Place a full load on the scale and remove it several times to exercise
the scale.
6. Enter calibration mode: Press ON/OFF key, then the right arrow key,
then the Clear key.
7. Make sure there is not load on the scale and press the Clear key.
8. Place 1/2 of capacity on the scale and press the Clear key.
9. Place a full capacity load on the scale and press the Clear key.
10. Remove half the weight and press the Clear key.
11. Remove all the weight and press the Clear key.
12. Calibration is now complete.
13. Disconnect the scale from the power supply.
14. Remove the service tool and reconnect the power supply.

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For 30kg scales, a stiffener plate must be used. See illustration below.
Stiffener plate
30kg/60lb Scales
Replacing Base Covers
If you need to replace a damaged base cover, break off all four cut-outs
from the new cover before replacing.
If you attempt to abandon the calibration procedure you will see the
following display:
You must start the calibration procedure again.
Aborting Calibration

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Illustrated Parts List

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Wiring Diagram
Power Supplies
PN Note
70682-260 High current AC adapter
70682-277 Universal In-line
Load Cells
Country PN Note
Blank 70718-623 Blank 15kg - No software
Blank 70718-385 Blank 30kg - No software