Service Instructions XM Series PDF

XM Series
Counter Service Scales
Service Instructions
ENGLISH
ABR35-000511-AA *AWT35-000511* 26-05-2010

©Avery Berkel, 2010. All rights reserved.
The information contained herein is the property of Avery Berkel (a division of ITW Ltd) and is
supplied without liability for errors or omissions. No part may be reproduced or used except as
authorized by contract or other written permission. The copyright and the foregoing restriction on
reproduction and use extend to all media in which the information may be embodied.
Trademarks and acknowledgements
Avery Berkel is a registered trademark in certain jurisdictions. All brands and product names used
within this document are trademarks or registered trademarks of their respective holders.
IMPORTANT
When programming or configuring the equipment you must ensure that you comply with all relevant
standards and legislation. The example settings given in this book may not be legal for trade with the
public.
Contents
page no.
1 Safety
1.1 Installation and service 8
1.1.1 Safe handling 8
1.1.2 ESD precautions 8
1.1.3 Electrical installation 8
1.1.4 Risk of electric shock 8
1.1.5 Service precaution 9
1.1.6 Replacing batteries 9
2 Product Overview
2.1 Documentation 12
2.2 Scale configuration options 13
2.2.1 XM series models 13
3 Scale Installation
3.1 Connections and power up/down 16
3.1.1 Location 16
3.2 Cable management 17
3.3 Fitting the XM200 angle display bracket 18
3.4 Front bezel 19
3.4.1 Adjustment 19
3.5 Peripheral devices 20
3.5.1 Wireless (RF) device 20
3.5.2 Other peripherals 20
3.6 Calibration 21
3.6.1 Service switch access 21
3.6.2 Loadcell 22
3.6.3 Gravity settings 22
3.6.4 Printer 22
3.6.5 Touchscreen calibration 23
3.7 Power up sequence 25
3.7.1 Warm start 25
3.7.2 Cold start 25
3.8 Customer hand over 26
3.8.1 Levelling the scale 26
3.8.2 Changing the keyboard insert 26
3.8.3 Changing label and receipt rolls 27
3.8.4 Printer cleaning 28
XM series Service Instructions 3

3.8.5 Scale cleaning 29
4 Service Procedures
4.1 Tools 32
4.2 Weigh plate, cross and top cover 33
4.2.1 Removing the weigh plate, cross and top cover 33
4.3 Printer servicing 34
4.3.1 Removing the print head 34
4.3.2 Removing the printer chassis 35
4.3.3 Removing the printer roller 37
4.3.4 Removing the label low and label gap sensors 39
4.3.5 Printer controller PCB and loom ID tags 40
4.4 Front bezel and housing 41
4.4.1 Removing the mainboard 41
4.4.2 Removing the operator display 44
4.4.3 Removing the keyboard 44
4.4.4 Touch screen assembly 45
4.4.5 Removing the speaker 45
4.4.6 Removing the bezel rear assembly 46
4.5 Power supply unit 47
4.6 Loadcell 48
4.6.1 Removing the service switch 49
4.6.2 Removing the inclinometer 49
4.7 Rear housing 50
4.7.1 Removing the customer display assembly 52
4.7.2 Removing the display 54
4.7.3 Removing the rear head-up assembly XM200 models 55
4.7.4 XM400 Removing the front bezel assembly 56
4.8 Front housing 57
5 Service Mode
5.1 Service mode overview 60
5.2 Entering and exiting service mode 61
5.3 Diagnostics 62
5.3.1 Initialise 62
5.3.2 Weighing 62
5.4 Service configuration 63
5.4.1 Configuration banks 63
5.4.2 Service setup 68
6 Schematics and Wiring

6.1 Schematic and wiring details 70
4 XM series Service Instructions

6.1.1 External connections 70
6.1.2 Internal connections 71
6.2 Modules 79
6.2.1 Mainboard 79
6.2.2 Printer controller 80
6.2.3 LVDS 81
6.2.4 Logo 81
6.2.5 Power supply unit 82
7 Software updates
7.1 Updating software 84
7.1.1 Software update methods 84
7.2 Test report 85
7.2.1 XM application software 85
7.3 Imaging utility 86
7.3.1 Accessing the Imaging Utility 86
7.3.2 Backup menu 87
7.3.3 Restore options 88
7.4 Memory 89
8 Communications
8.1 Networks 92
8.1.1 Scale networks 92
8.1.2 Network protocol 93
8.1.3 File sharing 93
8.2 Network setup 94
8.2.1 Network setup - wired 94
8.2.2 WLAN Network setup - RF comms (optional) 95
8.3 Network failure 97
8.3.1 Network reconciliation 97
9 Preventative maintenance
9.1 Checklist 100

Safety
Safety
1
This chapter contains information about possible hazards and precautions you should
take to minimize any risk.
Contents
1.1, Installation and service
1.1.1, Safe handling
1.1.2, ESD precautions
1.1.3, Electrical installation
1.1.4, Risk of electric shock
1.1.5, Service precaution
1.1.6, Replacing batteries

1.1 Installation and service Safety
1.1 Installation and service

Installation and maintenance of the equipment must only be carried out by trained and
authorised personnel.
1.1.1 Safe handling

When lifting, moving or supporting the machine, take its weight into consideration.
To avoid the risk of the machine falling, where applicable, ensure that it is placed securely
on a flat and level surface.
Do not use the front bezel or cross to handle the scale
1.1.2 ESD precautions

When handling printed circuit boards and electronic components:
O wear an antistatic wrist strap.
O ensure all electronic components/boards are stored appropriately. Use conductive/
antistatic work surfaces and packaging.
1.1.3 Electrical installation

The mains lead must be connected to a supply outlet with a protective earth contact. The
electrical supply at the socket outlet must provide over current protection of an
appropriate rating.
Pluggable equipment must be installed near an easily accessible socket outlet.
Permanently connected equipment must have a readily accessible disconnect device
incorporated in the fixed wiring.
1.1.4 Risk of electric shock

To avoid the possibility of electric shock or damage to the machine, always switch off the
machine and isolate it from the power supply before carrying out any routine maintenance
Always completely isolate the machine from the power supply before:
O removing the machine covers.
O performing any routine maintenance.
O cleaning the machine.

1.1 Installation and service Safety
1.1.5 Service precaution

O When the covers are removed, do not apply power to the unit unless specifically
instructed to do so in this handbook.
O When working on live equipment, take great care, use insulated tools and test
equipment, and do not work alone.
O When testing or fault finding, use extreme care. Ensure that any test equipment used
is in good condition and capable of withstanding the existing voltages.
O All tools used must have insulated handgrips. Test probes and jumper leads must be
in good condition with adequate insulation. Test probes with claw ends and jumper
leads must not have insecure parts that may fail during use.
1.1.6 Replacing batteries
CAUTION: RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT

TYPE. DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS.

Product Overview
Product Overview
2
This chapter contains information on the models available in the XM series and lists the
documentation relevant to XM Series System scales.
Contents
2.1, Documentation
2.2, Scale configuration options
2.2.1, XM series models

2.1 Documentation Product Overview
2.1 Documentation
Document title Part number
Quick User Guide - multilingual
English, German, French, Dutch, Spanish, Italian ABR35-000416
Danish, Norwegian, Swedish, Finnish, Estonian, English ABR35-000486
Latvian, Lithuanian, Hungarian, Romanian, Portuguese, English ABR35-000487
Slovenian,Croatian, Czech, Slovakian, Polish, English ABR35-000488
Russian, Ukrainian, Bulgarian, Greek, Turkish, English ABR35-000489
User Instructions - electronic format only
English ABR35-000520
German ABR35-000518
French ABR35-000514
Dutch, ABR35-000519
Spanish ABR35-000516
Italian ABR35-000517
Illustrated Parts List - electronic format only ABR35-000510-AA

2.2 Scale configuration options Product Overview
2.2 Scale configuration options

2.2.1 XM series models
XM100
OMonobloc
OCassette label/receipt printer in base

O Standard15kg AVR
O Options 30kg x 5g, 6kg AVR
XM200
OTower mounted customer display
OSelf service scale
O Standard 15kg AVR
O Option 30kg x 5g
XM400
OTwo piece scale with tower mounted
adjustable colour touch vendor display.
O15kg AVR

2.2 Scale configuration options Product Overview
XM600
OSystem printer
OIntegrated adjustable colour touch vendor
display
OOptional colour customer display and
connection pack.
O15kg AVR

Scale Installation
Scale Installation
This chapter provides information you may need for installing the scale
Contents
3
3.1, Connections and power up/down
3.1.1, Location
3.2, Cable management
3.4, Front bezel
3.4.1, Adjustment
3.5, Peripheral devices
3.5.1, Wireless (RF) device
3.5.2, Other peripherals
3.6, Calibration
3.6.1, Service switch access
3.6.2, Loadcell
3.6.3, Gravity settings
3.6.4, Printer
3.6.5, Touchscreen calibration
3.7, Power up sequence
3.7.1, Warm start
3.7.2, Cold start
3.8, Customer hand over
3.8.1, Levelling the scale
3.8.2, Changing the keyboard insert
3.8.3, Changing label and receipt rolls
3.8.4, Printer cleaning
3.8.5, Scale cleaning

3.1 Connections and power up/down Scale Installation
3.1 Connections and power up/down

Important:XM series machines should be connected to the mains power supply before
connecting USB/ethernet cables
WIFI connector
A
USB data device
ON/OFF switch
3.1.1 Location
Scales should be located on a firm, level surface in a draught free environment.
Figure 3.1 Typical counter installations
The scale has an inclinometer bolted to the loadcell assembly. If the scale is out of level
by more than 5° the ValuMax indicator will show a red cross in the display screen status
bar. The scale has four levelling feet to enable manual levelling up to 10mm.

3.2 Cable management Scale Installation
3.2 Cable management

XM100
Cable clips are provided in the

installation kit for ensuring that
cables do not become loose
during use or cleaning of the
scale. Use whichever size is
appropriate to clip the cables to
the scale.
XM600
Power supply lead clamping.

3.3 Fitting the XM200 angle display bracket Scale Installation
3.3 Fitting the XM200 angle display bracket

All XM200 machines are shipped with the optional angle bracket which allows the display
to be fitted at 90° to its normal position.
1.Remove the seal and screw

securing the rear moulding and the
column trim.
2.Slide the two covers up together

to remove them from the column.
Take care that the loom feeds
through the space in the rear
moulding.
3.Fit the angle bracket in the

orientation required taking care to
feed the loom through the space
provided.
4.Connect the loom and slide the
head moulding onto the angle
bracket.

3.4 Front bezel Scale Installation
3.4 Front bezel
3.4.1 Adjustment
1.To raise the front bezel assembly,

lift gently just using finger pressure,
until it locates on the ratchet at the
desired angle.
2
1
2.To lower the front bezel, press

the red lever located on the
underside of the assembly and
2 lower it until it locates on the
ratchet at the desired angle.
Insert cover
Inserting the programmable keyboard overlay.
1.Open the keyboard overlay

holder by pushing down on the
clip.
2.Lower the holder and
1 3. remove/replace the keyboard
2
overlay.

3.5 Peripheral devices Scale Installation
3.5 Peripheral devices

3.5.1 Wireless (RF) device
Dedicated USB connection for

WiFi device.
3.5.2 Other peripherals
Three USB connectors on the underside of the scale are provided for peripherals such
as:
O a hand scanner
O a cash drawer
O a wrapper.

3.6 Calibration Scale Installation
3.6 Calibration
3.6.1 Service switch access
1.Turn the cover plate latch to

unlock the access cover plate.
2.Break the paper seal and

remove both the paper seal and
the sealing plate.

3.Press the service switch (use a

piece of stiff wire such as a paper
clip).
3.6.2 Loadcell
1. Select Setup Mode from the menu bar
2. Select Service Mode
3. Select Engineer and enter the pin (9381) in the appropriate field.
4. Select Calibration
You will see the message ‘Empty Pan’, ‘Press continue when ready’.
5. Follow the instructions displayed on screen.
6. When you see the message ‘Deactivate service switch’, press the service switch
again.
3.6.3 Gravity settings

If you are calibrating the scale at a site other than one in the same gravity zone as the
previous calibration or the manufacturing site you must enter the site gravity value.
3. Select Engineer and enter the pin in the appropriate field.
4. Select Gravity.
5. Follow the instructions displayed on screen.
3.6.4 Printer
There are three sensors that will need to be calibrated if the main board is changed. They
are the:
O label gap sensor
O take up sensor
O media sensor.
The scale measures the amount of paper remaining on a roll and presents this
information on the vendor display

You will need to be in the Printer Setup function to be able to calibrate these sensors.
Each calibration function has on-screen instructions.
3. Select Engineer and enter the PIN in the appropriate field.
4. Select Service Setup
5. Select Printer Setup
6. Select Calibrate Sensors
Label gap sensor
1. Select Calibrate Gap Sensor
2. Follow the on-screen instructions.
Take up sensor
1. Remove cassette
2. Select Calibrate take Up Sensor
3. Rotate the take up spool clockwise as far as it will go and hold it.
4. Touch Continue on the display screen.
5. Release the take up spool and replace the cassette.
Media sensor
1. Select Calibrate Media Sensor
2. Follow the on-screen instructions.
3.6.5 Touchscreen calibration

You will find the touchscreen calibration function in Manager Mode.
Note: You can also access the touchscreen calibration by holding down the menu bar key
for approximately 10 seconds from the product selection screens. When the key is
released the scale goes into touchscreen calibration.
1. Ensure that the touchscreen is in the position in which it will be used during normal
operation.
3. Select Manager Mode.
4. Select Machine Setup
5. Select Touchscreen Calibration

6. Follow the on-screen instructions, touching the crosshairs in each position that they
appear.
Note: Touch the crosshair for about one second to give the software time to register the
position.

3.7 Power up sequence Scale Installation
3.7 Power up sequence

3.7.1 Warm start
When the scale is powered up and switched on, communications are opened with all
other scales in the network via the ISC channel.
If the scales is configured as a client it will:
O periodically attempt to connect to other scales in the network if the connection is
missing.
O compare its database with the server’s database.
O if necessary, copy the server database to itself.
O start its status checking process.
O trade as normal.
3.7.2 Cold start

You will need to cold start a scale if you have replaced the main board or you are
installing a ‘clean scale’ straight from the factory. When the scale ‘powers up’ you will be
prompted to enter:
O the host (computer) name
O the standard IP address/hostname for the scale
O the scale’s role, e.g. client, server
The scale then goes through the warm start procedure.

3.8 Customer hand over Scale Installation
3.8 Customer hand over

When installing a scale at a customer site always ensure that the customer knows the
best way to look after and maintain the scale on a regular basis to for trouble free use.
3.8.1 Levelling the scale

The scale has four adjustable feet to enable manual adjustment of the scale.
When the scale is operating the
ValuMax levelling compensation
levelling foot system provides accurate
weighing even when the scale is
not level (up to 5 degrees from
horizontal). An icon is displayed in
the status bar to indicate that
ValuMax is operating.
A screen message indicates by
how much the screen is out of
level and where.
3.8.2 Changing the keyboard insert
1.Open the keyboard overlay

holder by pushing down on the clip.
2.Lower the holder and
3. remove/replace the keyboard
1 overlay.
2

3.8.3 Changing label and receipt rolls
1.Pull the red handle until it clicks

and then pull out the cassette to
remove it from the machine.
Ensure that the locating pin is
aligned correctly with the cassette.
1 1.Remove the old label roll core.

2.Check that the new label roll is of
the right type and size and insert
the roll into the cassette.
label roll guide

3.Remove approximatelt 40cm of
label/paper and feed the paper
paper width guide over the rewind spindle under the
paper guide bar then over the
paper guide.

4. Adjust the paper width guide to fit the width of the labels and the label roll guide to
retain the roll on the hub.
5.Replace the cassette ensuring

that it is correctly located. Push in
the red handle.
If the cassette is not fully located
you will see a message on the
screen.
3.8.4 Printer cleaning

Clean the cassette front plate
using a clean cloth moistened with
water containing a small amount of
mild detergent
Print head
We recommend that the print head is cleaned daily in order to ensure maximum life and
to maintain the print quality.
The print head should be cleaned using the specified head cleaning kit available from
your Avery Berkel supplier.
Always follow the instructions on the cleaning kit.

3.8.5 Scale cleaning
CAUTION: Harsh abrasives, solvents, scouring cleaners and alkaline cleaning solutions,
such as washing soda, should not be used especially on the display windows. Under no
circumstances should you attempt to wipe the inside of the machine.
The exterior may be wiped down with a clean cloth moistened with water containing a
small amount of mild detergent (washing up liquid).
Cleaning the touchscreen
Use a mild detergent sprayed onto a damp cloth. Fold the cloth several times to avoid
applying undue pressure to the screen. Do not spray the detergent directly onto the
screen. Do not use sharp objects such as screwdrivers, knives, pens or fingernails which
may damage the screen.

Service Procedures
Service Procedures
This chapter describes common service and maintenance procedures.
Contents
4
4.1, Tools
4.2, Weigh plate, cross and top cover
4.2.1, Removing the weigh plate, cross and top cover
4.3, Printer servicing
4.3.1, Removing the print head
4.3.2, Removing the printer chassis
4.3.3, Removing the printer roller
4.3.4, Removing the label low and label gap sensors
4.3.5, Printer controller PCB and loom ID tags
4.4, Front bezel and housing
4.4.1, Removing the mainboard
4.4.2, Removing the main board
4.4.2, Removing the operator display
4.4.3, Removing the keyboard
4.4.4, Touch screen assembly
4.4.5, Removing the speaker
4.4.6, Removing the bezel rear assembly
4.5, Power supply unit
4.6, Loadcell
4.6.1, Removing the service switch
4.6.2, Removing the inclinometer
4.7, Rear housing
4.7.1, Removing the customer display assembly
4.7.2, Removing the display
4.7.3, Removing the rear head-up assembly XM200 models
4.7.4, XM400 Removing the front bezel assembly
4.8, Front housing

4.1 Tools Service Procedures
4.1 Tools
In order to carry out the service and maintenance procedures in this book you will need
the following tools:
O Torque wrench
O Magnetic screw drivers
O Torx drivers
O Hexagon socket wrenches
O Cross head drivers

4.2 Weigh plate, cross and top cover Service Procedures
4.2 Weigh plate, cross and top cover
4.2.1 Removing the weigh plate, cross and top cover
1 1.Lift off the weigh plate.

2.Remove the rubber bung from
the cross and undo the two socket
head bolts securing the cross.
3.Remove the cross.
To remove the cover:
4.Remove the service switch
access cover.
3
2
5.Remove the nine bungs and
screws securing the top cover.
To replace the weigh plate, cross
and top cover reverse the
4 procedure for removing them.
Important:When refitting the cross
ensure that it lines upwith the
edged indicator triangles on the top
5
cover. Failure to do so may cause
incorrect weighings.
CAUTION: When replacing the top

cover, take care not to trap the loom
from the printer controller board to
the logo board between the front
cover and the top cover.

4.3 Printer servicing Service Procedures
4.3 Printer servicing
4.3.1 Removing the print head
CAUTION: Do not remove the printer head while the scale is powered on.
Note: Printer door/cassette assembly already removed.
If the cassette ticket mouth is damaged the complete assembly must be replaced.
1.Use a screw driver to lever/unclip

the printer head.
2.Pull out the printer head.

4.3.2 Removing the printer chassis

Preparation
1.Disconnect the printer stepper

motor loom.
2.Remove the fixing screw.
3*
3.(XM100) Loosen the rear cover
screw and mover the rear cover
slightly out of the way.
(XM200/XM400) Remove rear
cover/column assembly.
3*

4.Disconnect stepper motor loom

from printer.
5.Disconnect ribbon cable loom

from printer (not from printer
board).
Removal
6.Slide the printer chassis towards

2
the back of the machine and lift it
out.
1

4.3.3 Removing the printer roller

1.Remove the three screws and the

end cap.
2.Remove the bush and keep it for

fitting to the new roller.
3.Remove the roller using

pliers while holding the
drive gear in place.
4.Remove the bush from
the other end of the roller
and keep it for fitting to the
new roller.

5.Insert the new roller.

6.Replace the bush with
the flat edge facing directly
downwards as shown in
the illustration.
7.Replace the second bush with

the flat edge facing directly
downwards as shown in the
illustration.

4.3.4 Removing the label low and label gap sensors

Label gap sensor
1.Remove the printer chassis see

page 35.
2.Disconnect the printer ribbon
1 cable from the printer board.
3
3.Disconnect the other ribbon
cable from the take up motor.
2
4.Cut the tie wrap from around the
looms.
5.Disconnect the two motor looms
and the label gap sensor loom
from the board.
6.Remove the four torx screws

securing the motors and heat sink
and remove the motors and heat
sink.
7.Remove the label gap sensor.
Take care when feeding the
sensor loom through the cable gap
in the chassis.

1.Remove the torx screw securing

the label gap sensor.
2.Remove the label gap sensor.
Take care when feeding the
sensor loom through the cable gap
in the chassis.
Label low sensor

1. Remove the two torx screws securing the label low sensor and disconnect the loom
from the printer interface board.
4.3.5 Printer controller PCB and loom ID tags
J7 ID Loom
J6 J1 Main motor
J5
J3 Media sensor
J3 J4 Take Up torque sensor
J1
J5 Label Gap sensor
J4 J6 Take Up motor
J7 Cassette micro-switch

4.4 Front bezel and housing Service Procedures
4.4 Front bezel and housing

Important:When the main board is replaced:.
O make a backup of the scale configuration and product data.
O remove the SD and keep it safely to be inserted on the new mainboard

O the printer must be recalibrated
4.4.1 Removing the mainboard
1.Remove the three screws from

2
the front of the bezel.
2.Flip the lid over taking care that
the looms have enough movement
to allow this.
3.Disconnect the four looms from

the main board.

1.Release the clips on the

1 connector and
2.disconnect the display tail.
1
2
1.Disconnect all the looms.

3 1.Remove the two screws

securing the mainboard to the
touchscreen assembly.
1 2.Slide the board out from under
the clips and
3.lift the board off taking care not
to damage the display tail.
Note: When the main board is replaced the printer must be recalibrated.
Important:When replacing the mainboard take care to thread the display tail through the
mainboard and ensure that the tail is not trapped.

4.4.2 Removing the operator display
1.Remove the main board as

described in section 4.4.2, page
40.
2.Disconnect the display loom.
3.Remove the four screws
securing the display carrier
moulding to the touchscreen
assembly and lift off the display.
4.4.3 Removing the keyboard
1 1.If the mainboard has not been

removed, disconnect the two looms
from the mainboard.
2 2.Remove the four screws
securing the keyboard to the
touchscreen assembly.
3.Lift off the keyboard.

4.4.4 Touch screen assembly

Note: The touchscreen and bezel are only available as an assembly.
4.4.5 Removing the speaker
3 1.Disconnect the loom.
1 2.Prise open the clips and lift the

speaker assembly free from them.
3. Remove the four screws
securing the speaker to the
bracket.
1
2

4.4.6 Removing the bezel rear assembly
4. Remove the two screws securing the front bezel assembly to the scale body and lift
the bezel free.

4.5 Power supply unit Service Procedures
4.5 Power supply unit
1 A.Remove the screw securing the

top cover.
1 B.Slide the top cover in the
direction of the arrow.
1 C.Remove the cover.
2 A.Disconnect the mains power

supply loom and the printer loom.
2 B.Remove the four screws
securing the power supply unit and
remove it from the cover base.
Reverse the procedure when fitting
the power supply unit.

4.6 Loadcell Service Procedures
4.6 Loadcell
1.Remove paper seal, seal and

screw.
2.Slide cover in direction of arrow

and lift the cover off.
3.Disconnect the loadcell and

service switch looms.

4.6 Loadcell Service Procedures
4.Remove the four screws securing

the loadcell and remove the loadcell
assembly.
Reverse the procedure when fitting
the loadcell.
4.6.1 Removing the service switch
1.Disconnect the service switch

loom from the loadcell assembly.
2.Remove the two screws
securing the service switch.
Reverse the procedure when
fitting the service switch.
4.6.2 Removing the inclinometer
1.Disconnect the loom.

2.Remove the two screws
securing the inclinometer to the
loadcell.
Reverse the procedure when
fitting the inclinometer.

4.7 Rear housing Service Procedures
4.7 Rear housing

Figure 4.1 Removing the rear cover
3
4
1. Loosen the rear cover screw.

2. Gently pull the rear cover away from left side moulding.
3. Remove the tie wrap.
4. Disconnect the display loom.

Removing the column assembly (200 and 400 models)

(XM200 shown)
1.Release the customer display

loom from the three cable clips.
2.Remove the hexagon cap screw
and the recessed pan head screw.

4.7.1 Removing the customer display assembly

XM100 model
1.Remove the clips and

2.lift out the customer display.
2 Important:Do not lose the clips.
1
1 3.Cut the tie wrap and

4.disconnect the display loom.

XM200 and XM400 models

Note: XM200 shown
1.Remove the two screws from the

back of the customer display
housing.
2.Unclip display from the moulding

bezel and the display window.
1
3.Cut the tie wrap and
4.disconnect the display loom.
Note: If there is insufficient cable to
enable you to disconnect it, ease
2 the loom up out of the column until
you have enough length of cable.

4.7.2 Removing the display
1.Release the clips on the

connector and
2.disconnect the display tail.
1
2
3.Slide the board backwards and

lift it out.
1
3
4.Remove the display from the

display carrier moulding.
Replacing the display

Reverse the procedure for removing the display taking care not to trap the display tail
loom.

4.7.3 Removing the rear head-up assembly XM200 models
1.Remove the seal and screw

securing the rear moulding and the
column trim.
2.Slide the two covers up together

to remove them from the column.
Take care that the loom feeds
through the space in the rear
moulding.

4.7.4 XM400 Removing the front bezel assembly
1.Remove the three screws from

the front of the bezel.
2.Flip the lid up taking care that
the looms have enough
movement to allow this.
3.Disconnect the four looms from
the main board.
Note: To remove the main board
follow the instructions in section
4.4.1, page 41.

4.8 Front housing
Removing front and left side cover
3
3
Remove the front bezel assembly (See Front bezel and housing on page 41).
1. Free the looms from the three cable clips holding them in position.
2. Remove the two screws securing the covers.
3. Remove the ‘L’ shaped front and side moulding.
4.8 Front housing Service Procedures

Service Mode
Service Mode
When programming the scale you must ensure that you comply with all relevant
standards.The example settings given in this book may not be legal for trade.
5
Contents
5.1, Service mode overview
5.2, Entering and exiting service mode
5.3, Diagnostics
5.3.1, Initialise
5.3.2, Weighing
5.4, Service configuration
5.4.1, Configuration banks
5.4.2, Service setup

5.1 Service mode overview Service Mode
5.1 Service mode overview

There are two levels of service mode:
O Full service access
allows access to all service functions including scale calibration.
O Restricted service access
Access is limited to non-secure service functions.
Service Mode
Configuration Calibration
Gravity Data Maintenance
Diagnostic Tests Service Setup

Gravity Settings Database Table Selection
Weighing Initialise
Machine Details Printer Setup

Warm Start Cold Start
Rebuild Totals
Secure Non-Secure
Load Translations Calibrate Sensors
Calibrate Gap Sensor Calibrate Media Sensor Calibrate Media Sensor
Figure 5.1 Service Mode functions

5.2 Entering and exiting service mode Service Mode
5.2 Entering and exiting service mode

There are two levels of service funtionality Restricted and Full service access. To use
Restricted Service mode you do not need to break the weights and measures seal and
activate the service switch.
In restricted mode you can :
O configure non-secure scale functions
O change gravity settings
O run diagnostic tests
O load translations
O access data maintenance tables
O use service setup to calibrate printer settings and check machine details
O rebuild totals
In full service mode you can:
O calibrate the scale
O onfigure secure scale functions
Display the menu bar and then touch Setup Mode to go to the setup mode menu.
Full service access
For full service access you will need to:
1. remove the access panel from the scale top cover
2. use a suitable tool to depress the service switch located on the loadcell assembly.
See 3.6.1, Service switch access, page 21.
Note: When you exit Service Mode you will be prompted to de-activate the service switch.
Press the service switch again to de-activate it.
Restricted service access

Service PIN
Use the fixed numeric keys to enter the PIN when the PIN field is highlighted. The default
service PIN is 9381.

5.3 Diagnostics Service Mode
5.3 Diagnostics
5.3.1 Initialise
Cold start
Important:You should always take a backup of the scale data using MXTool before
initiating a cold start.
Selecting Cold Start will delete the scale database. The operating system then looks for
the files mossysa and mossysb and if it can’t find them it creates them with some default
settings For further information see 3.7.2, Cold start, page 24.
Warm start
Selecting Warm Start will initiate the same power up sequence as if the scale is switched
off and on. For further information see 3.7.1, Warm start, page 24.
5.3.2 Weighing
On completion of the weighing test you will see the weighing status display.

5.4 Service configuration Service Mode
5.4 Service configuration

5.4.1 Configuration banks
Service configuration options are split into two banks of data, secure and non-secure.
Non -secure data may be edited through restricted access using the service PIN. Secure
data may only be edited by accessing service through the service switch.
Secure configuration data
Option Type Default
1 Capacity 9
0. User Defined 10. 25kg x 5g

1. 25lb x 1/8oz 11. 30kg x5g
2. 30lb x 0.01 12. 30kg AVR
3. 50lb x 0.01 13. 30lb/15kg
4. 6kg x 1g 14. 60kg x 20g
5. 6kg x 2g 15. 150kg x 50g
6. 6kg AVR 16. 300kg x 100g
7. 12kg x 2g 17. 60kg x 10g
8. 15kg x 5g
9. 15kg AVR
2 Tare System 0
0. Free 4. Free, Stored

1. Free, Graduated 5. Free, Graduated, Stored
2. Free, Cumulative, Graduated 6. Free, Cum, Grad, Stored
3. Free, Cum, Grad, Proportional 7. Free, Cum, Grad, Prop, Stored
3 Tare Display 0
0. Negative weight display

1. Separate Tare & Negative Weight
4 Weight Filter 2
0. Settling time 0.25Hz 2. Settling time 1.00Hz

1. Settling time 0.50Hz 3. Settling time 2.00Hz
5 Unit Price 0
0. 6 Digit UP and TP 2. 5 Digit UP, 6 Digit TP

1. 6 Digit UP and TP, Dummy zero 3. 8 Digit UP and TP
6 Transaction Rounding 0
0. Round to nearest 1 2. Round to nearest 10

1. Round to nearest 5 3. Round to nearest 25

Option Type Default
7 Price Decimal Places 2
0. Unit Price = 0, Total Price = 0 3. Unit Price = 3, Total Price = 3

1. Unit Price = 1, Total Price = 1 4. Unit Price = 0, Total Price = 1
2. Unit Price = 2, Total Price = 2 5. Thousands Separators
8 Punctuation 0
0. Decimal Point 2. Arabic Inverted Comma

1. Comma
9 Currency Symbols 1
00. Custom 10. Lit 20. Pta 30. Won 40. Q 50. SR
01. £ 11. P 21. Rp 31. bt 41. TL 51. YR
02. $ 12. E 22. mk 32. Pts 42. F (Belg.) 52. Ft
03. R 13. K 23. ΔΡΧ 33. EEK 43. BD 53. kn
04. F (French) 14. M 24. SR 34. Lt 44. LE 54. Lm
05. Kr 15. D 25. z? 35. € 45. JD 55. Ksh
06. DM 16. RM 26. Kc 36. Eur 46. KD 56. RON
07. S 17. L 27. SK 37. R$ 47. LL 57. ROL
08. ƒ 18. N$ 28. kr 38. B 48. RO 58. LEI
19. Esc 29. Dhs 39. C 49. QR
10 Receipt Rounding 0
0. Round to nearest 1 2. Round to nearest 10 4. Round to nearest 50

1. Round to nearest 5 3. Round to nearest 25 5. Round to nearest 100
11 Dynamic Filter 0
0. Disabled 2. 2 divisions 4. 4 divisions

1. 1 division 3. 3 divisions 5. 5 divisions
12 Balance Key Range 0
0. ±2% 1. ±5%
13 +15% -5% Balance At Start up 1
0. Disabled 1. Enabled
14 Automatic Balance 1
15 Reduced Zero Tracking 0

Option Type Default
16 Tare Cancellation 3
0. None 2. Zero Key

1. Tare Key 3. Tare & Zero Key
17 Price Interlock/NTEP Operation 0
0. Disabled 1. Price & Tare 2. NTEP Operation

18 Receipt Total Currency Symbols 1
19 Minimum Prepack Weight 1
20 Prepack Allows Stored/Graduated Tares 1
21 Receipt Algorithms (Receipt/Display) 1
Algorithm Weighed n x (+ve Non-Weighed n x (-ve Non-Weighed)

0| A 1/1 1/1 0/1
1| B 1/1 1/1 1/1
2| C 1/1 n/1 0/1
3| D 1/1 n/1 n/1
4| E 1/1 n/1 0/0
22 Receipt Formats 1
0. Standard format with heading line which includes tare weight.

1. No symbols line, symbols printed with transaction data. First line contains text and total price.
Second line contains weight/multiplier and unit / item price.
2. As receipt format 1 except total price printed on third line for weighed.
3. Symbols line. First line contains text. Second line contains weight/multiplier, unit / item price
and total price.
4. Each transaction contains its own symbols line.
5. USA receipt format. Identical to format 1 except that 'X' and 'Items' is replaced by '@' .
6. Australian receipt format. Identical to format 5 except description not allowed to intrude on the
total prices column.
23 Net Weight 0
0. Grams 1. oz - lb/oz
24 USA Total Price Legend 0

Option Type Default
25 Back Calculation Of Unit Price 0
0. Disabled 2. Using Actual Weight 4. By Product Type

1. Using Net Weight (100g) 3. Using Net Weight (kg) 5. By PLU
26 Frequent Shopper Algorithm 0
Compute frequent shopper price from printed weight

Compute frequent shopper price from back-calculated weight
Compute frequent shopper price from saving and back-calculated weight
Frequent shopper price scheme 3
Non secure configuration data
Option Type Default
1 Minimum Weight Disturbance 0
0. 1 Division 3. 20 Divisions
1. 4 Divisions 4. Return to below Portè Minimal
2. 10 Divisions
2 Bleep Behind Zero 0
3 Numeric Entry Timeout 0
4 Product Recall Timeout 2
Value entered in 100ms Intervals

5 Receipt Tax Printing 0
0. No Tax 2. Itemised Tax

1. Totals Tax
6 Printer Type 0
0. None 2. Label Only

1. Receipt Only 3. Label & Receipt
7 Machine Type 0

Option Type Default
8 Add Function 0
0. None 3. Receipt Only

1. Transaction + Total 4. Transaction & Receipt
2. Total Only
9 Date Type 0
0. Numeric with '-' separator 2. Alpha with '-' separator

1. Numeric with '.' separator 3. Alpha with '.' separator
10 Date Format 0
0. DD MM YY 3. DD MM YYYY
1. MM DD YY 4. MM DD YYYY
2. YY MM DD 5. YYYY MM DD
11 Maximum Sequence Number 0
12 Auto Sub-Total Display 0
13 Sub-Total Display Timeout 0
Value entered in 100ms Intervals

14 Print head DOT Monitoring 0
15 Time in Date One Field 0
16 Leading Zero Suppression 0
17 Printed Boxes 0
18 One Shot Functions 0
19 Self Cancelling Tare 0
20 Fix Options 0

Option Type Default
21 Cash Drawer With Zero Totals 0
22 Price1/Price2 Field Swap 0
23 Tax System 0
0. Inclusive 2. Inclusive POS only

1. Exclusive 3. Exclusive POS only
24 Tax Reference in Description 0
25 Condensed Printing 0
26 Change Calculation 0
27 Direct Entry Prepack 0
28 Numeric System 0
0. English (Arabic) 1. Hindi
5.4.2 Service setup

Note: For calibration details see Section 3.6, Calibration, page 21
Printer Setup
O the gap sensor
O the take up sensor
O the Media sensor

Schematics and Wiring
Schematics and Wiring

6
This chapter contains layout and electrical information for PCBs and hardware within the
scale.
Contents
6.1, Schematic and wiring details
6.1.1, External connections
6.1.2, Internal connections
6.2, Modules
6.2.1, Mainboard
6.2.2, Printer controller
6.2.3, LVDS
6.2.4, Logo
6.2.5, Power supply unit

6.1 Schematic and wiring details Schematics and Wiring
6.1 Schematic and wiring details

Note: USB connectors are USB2 compatible.
6.1.1 External connections

XM series scales have five USB interfaces four of which are located beneath the scale.
One of these four sockets is reserved for use with a USB Wifi device while the remaining
three are can be used for peripherals such as scanners or cash drawer.
The fifth USB interface is in the printer compartment (except XM410) and provides a
means to backup and restore scale software and data including kernel, root file system,
application and user data. It is intended for local download and upload of scale data via a
USB mass storage device.
On XM410 machines this USB interface is located in the right hand side panel.
Scanner/large keyboard
Mains supply
Wrapper
Cashdraw
Remote platform
Wifi USB connector

RJ45 Ethernet network
connection
Peripherals
External devices such as hand scanners, large keyboards, cash drawers, wrappers and
remote platforms communicate with the scale via USB2 connections on the underside of
the scale.
Scanner settings
The scanner must be configured to interpret EAN/UPC family barcodes or Code 39
barcodes. The type of barcode will depend on the application being used.
Refer to the instructions supplied by the scanner manufacturer for details on how to do
this.

6.1.2 Internal connections

Power and printer XM100, XM200, XM300, XM400
Printer
Power Supply Unit
ABR25-000664 ABR25-000662
Mains Filter
Power Switch
ABR25-000665
ABR25-000670
Printer Control
Print Head
ABR25-000671
Illuminated Ticket Mouth

ABR25-000675
USB
USB
ABR25-000675
ABR25-000793
Left Side Cover Base Casting

Power and printer XM410
Power Supply Unit
ABR25-000664 ABR25-000662
Mains Filter
Power Switch
ABR25-000665
Printer Control
ABR25-000671
Illuminated Ticket Mouth
ABR25-000675
USB
USB
ABR25-000675
ABR25-000793

Power and printer XM600
Mains Filter
ABR25-000662
Printer
Power Switch
ABR25-000664
Power Supply Unit
ABR25-000670
ABR25-000664
USB
Print Head ABR25-000867
ABR25-000671 Illuminated Ticket Mouth
ABR25-000793

Loadcell, display and keyboard XM100, XM200, XM400
ABR25-000683
ABR25-000684(XM400)
ABR25-000685(XM200)
ABR25-000682
Rear Display
ABR25-000666
ABR25-000672
ABR25-000679
Printer Control
ABR25-000676
Transducer Assembly
Service Switch
ABR25-000692
Speaker
Transducer
ABR25-000691 ABR25-000795
Inclinometer
Mainboard & Front Display
ABR25-000688
Touch screen Loom
ABR25-000682
Keyboard

Loadcell, display and keyboard XM410, XM420
Door Open Switch /

Paper Low LED
Clamshell Printer
ABR25-000684
ABR25-000682
Printer Head Paper Feed

Motor Drive
Rear Display
To Fan
Clamshell Printer PCB
ABR25-000666
ABR25-000672
ABR25-000679
Power
Printer Control
ABR25-000676
Transducer Assembly
USB Data
Service Switch
ABR25-000692
Speaker
Transducer
ABR25-000691 ABR25-000795
Inclinometer
ABR25-000688
Touch Screen Loom
ABR25-000682
Keyboard

Loadcell, display and keyboard XM300
Self Service Keyboard (Optional) Self Service Keyboard
ABR25-000666
ABR25-000672
ABR25-000679
Printer Control
ABR25-000676
Transducer Assembly
Service Switch
ABR25-000692
Speaker
Transducer
ABR25-000691 ABR25-000795
Inclinometer
ABR25-000688
Touch Screen Loom
ABR25-000682
Keyboard

Main board, display and keyboard XM600
Speaker
ABR25-000795
ABR25-000688
ABR25-000682
ABR25-000679
ABR25-000666
Keyboard
ABR25-000672
ABR25-000841
I/O Board
ABR25-000840 (x3)
Printer Control

Loadcell connections
Loadcell/inclinometer
Loadcell USB
Loadcell/Service switch assembly

6.2 Modules Schematics and Wiring
6.2 Modules
6.2.1 Mainboard
11 12 1 13
6t
10 9 8 7
Note: SD card (factory fitted) is used only for media files. When replacing the mainboard
the SD card you will need to remove the card from the defective board and fit it to the new
mainboard.
1. Display tail
2. Connector - loom to speaker
3. Connector - loom to keyboard
4. Connector - loom to touchscreen
5. USB connector - loom to clamshell printer if fitted
6. Connector - power supply loom to clamshell
7. USB connector
8. Connector - loom to column mounted/customer display
9. Connector -ethernet
10.Connector - power supply
11.SD card

12.Switch - factory use only

13.Reset button
Asset management
Asset management information is printed on the test report.
O Software versions
O Wired setup
O Network setup
O Miscellaneous setup
6.2.2 Printer controller
12
1
11
3
10
9
4
7 6
1. CON 5 - loadcell interface

2. CON 9 - loom to thermal print head
3. CON12 - loom to printer display LEDs
4. CON6 - USB connector - WiFi USB port
5. CON7 - USB connector - memory expansion

6. CON8, CON10, CON11 - external USB ports

7. CON14 - external ethernet interface
8. CON13 -ethernet interface loom to mainboard
9. CON4 -USB interface loom from mainboard
10.CON1- DC out to loadcell
11.CON2 - DC in from PSU
12.CON3 on reverse - loom to printer
6.2.3 LVDS
MODE CONTROL
HS/VS DE
SW1A ON OFF
SW1B OFF ON
SW2A ON OFF
SW2B ON OFF
The four switches are set according to the table printed on the circuit board and shown
here. For XM set for HS/VS and for XT set for DE.
6.2.4 Logo

6.2.5 Power supply unit
2 1
1. Power supply in
2. Power supply - loom to printer controller PCB

Software updates
Software updates
7
This chapter contains information on updating software or firmware in your scale.
Contents
7.1, Updating software
7.1.1, Software update methods
7.2, Test report
7.2.1, XM application software
7.3, Imaging utility
7.3.1, Accessing the Imaging Utility
7.3.2, Backup menu
7.3.3, Restore options
7.4, Memory

7.1 Updating software Software updates
7.1 Updating software
7.1.1 Software update methods

Flash memory (USB) via the USB connector in the printer compartment.
USB interface
The USB interface is in the printer compartment (except XM410/XM600) and provides a
means to backup and restore scale software and data including kernel, root file system,
application and user data. It is intended for local download and upload of scale data via a
USB mass storage device.
To upgrade the scale software:
1. save the .ipkg package to a USB memory drive in a folder named ‘xm_update’
2. Insert the USB memory drive intp the USB port in the printer compartment and power
up the scale.
The scale will detect the presence of a new upgrade package and will install it as part of
the boot sequence.
Important:We recommend that you take a backup of the scale data using MXTool before
upgrading the software.
The application software can be upgraded with the following files.

xm01-utilities_x.x.x.x_arm.ipk
xm02-mainapp_x.x.x.x_arm.ipk
xm03-r76_x.x.x.x_arm.ipk
xm-printer-firmware-app_x.x.x.x_arm.ipk
Main XM application software:
xm-loadcell-firmware-app_x.x.x.x_arm.ipk

7.2 Test report Software updates
7.2 Test report

Asset management information and software versions are listed at the top of the Test
Report. To print a test report:
1. Press on the fixed keypad.
2. Touch
3. Touch to print the report.
7.2.1 XM application software

The test report lists the current versions of the software as:
Main Board Software
Application
Validation Library - validates any updates
Legally Relevant Library - contains computations and weighing functions related
software.
Utilities Software - contains programs enabling updates to and loading from
MXTool and USB storage devices.
Printer software version
O Line one - printer application
O Line two - printer software boot loader
Loadcell software version
O Line one - loadcell application
O Line two - loadcell software boot loader
Kernel Software version
Backup Kernel Software version
Root File System Software
Redboot Software version

7.3 Imaging utility Software updates
7.3 Imaging utility

This section describes the XM backup/restore image utility that allows an engineer to:
O make a complete image backup of one machine in order to clone another machine.
O backup/restore a number of sections of the Operating System to and from a USB
drive.
O The names of the files created on the USB drive are fixed.
O When performing a backup files of the same name will be overwritten if they exist.
There will be no warning.
O When doing a restore, the files must be named exactly as described. All files must
be lower case. Each file will also be accompanied by a checksum file.
xm-kernel mtd3_xm-kernel.img The .sum file is a md5 checksum of the .img

mtd3_xm-kernel.img.sum
bu-kernel mtd4_bu-kernel.img The .sum file is a md5 checksum of the .img
mtd4_bu-kernel.img.sum
root mtdblock5_root.tar The .sum file is a md5 checksum of the .tar
mtdblock5_root.tar.sum
usre mtdblock6_user.tar The .sum file is a md5 checksum of the .tar
mtdblock6_user.tar.sum
7.3.1 Accessing the Imaging Utility

To access the imaging utility:
1. Switch off the scale and ensure there is no USB drive connected.
2. Switch on the scale.
3. Hold down the F and 00 keys until the XM start up screen appears. After a few seconds
the imaging utility will initialise.
4. Enter the PIN (9381) when requested.
5. Plug in the USB drive and wait 10 seconds before pressing keys to select any further
options

You will now see the Image Utility main menu. Use the fixed keypad to select the option
you want.
Note: If the scale application starts as normal then it has not detected the key presses
during the scale initialisation. Switch off the scale and repeat from step1.
Backup
Press 1 to display all the backup options. Select the files you want to back up to the USB
drive.
Restore
Press 2 to display all the restore options. This menu allows you to restore any files, with
the fixed naming convention, already present on the USB drive.
Run fixed script
This option is currently reserved for future use.
In the future this option would enable you to update certain files from a specific script
supplied to you.
Quit and reboot
Press C to exit the Image Utility and reboot the scale.
7.3.2 Backup menu

Selecting Backup displays the following options:
Root filesystem (1)
Selecting Root File System backs up the file system, XM application files, database,
media, OS libraries etc.
Note: It should be noted that the printer and loadcell firmware is an exception and
currently no mechanism exists for backing thesefiles.
User filesystem (2)

The User File System is a partition of 128MB and is currently not used.

main XM-kernel (3)

This partition of approx 3MB is the most central component of the XM's operating system
but is dependent on the existence of the Root File System. It is not envisaged that the xm
kernel will be modified on a regular basis and you should only backup and restore this if
instructed.
Backup bu-kernel (4)
The bu-kernel is the backup kernel and is a separate drive partition of around 8MB. This
partition is the location from which the Imaging Utility is run. You would only need to
backup and restore this partition if changes have been made to the utility itself, such as
bug fixes or feature enhancements.
7.3.3 Restore options

The restore menu display options to restore any of the files as described in 7.3.2, Backup
menu.

7.4 Memory Software updates
7.4 Memory
256MB of flash memory
The flash memory holds the boot loader, application and system settings. These are
loaded into the SDRAM (128MB capacity) when required for use. Customer data, market
configuration, product database (local to customer) and activity logs (local to a single
scale) are also stored in and operated from the flash memory. There is approximately
170MB available for customer data.
2GB SD Card (optional)
Third party data such as videos, sounds, images are stored on the SD Card.

Communications
Communications
8
The inter-scale networks are configured in a Client/Server arrangement with all scales
sharing the same Ethernet ‘port address’ with the Server being responsible for all Host
data transfers.
Host connected scale networks can be arranged as ‘Multi-Server’ where each scale
operates as an independent Server, each having a direct connection to the Host device.
Contents
8.1, Networks
8.1.1, Scale networks
8.1.2, Network protocol
8.1.3, File sharing
8.2, Network setup
8.2.1, Network setup - wired
8.2.2, WLAN Network setup - RF comms (optional)
8.3, Network failure
8.3.1, Network reconciliation

8.1 Networks Communications
8.1 Networks
A network allows a number of scales to be connected together in an interscale network
and to a back office host. Scale networks can be connected physically in an ethernet
setup or WLAN.
O Inter-scale networks are configured in a client/server setup and each client is
configured with the host name of it’s server. The number of clients that can be
supported on a network will depend on server performance.
O Host connected networks can be configured as multi-server
O Scales on a network can share resources and information (operators, PLUs etc.).
8.1.1 Scale networks

O Ethernet as standard, 10/100 base-T auto switch
O Number of machines - 31 per network
Note: Smaller networks of five to ten machines are recommended to increase network
resilience.
O Networking host I/f - ethernet as standard

O DHCP/DNS or static IP addressing modes
Server/client networks
O One scale is configured as the server and holds the reference database. The back
office host communicates with this scale.
O Other scales in the same network are configured as clients and hold their own copy of
the database.
O Floating vendor is allowed.
O Prices and products can be updated at any of the scales.
Multi-server networks
O Each scale is configured as a server. If there is a back office host it will communicate
with all the scales.
O Each scale holds its own unique product file.
O Floating vendor is not allowed.

8.1 Networks Communications
Peer groups
S = server
C = Client
Host
S S S S
Peer Group
C C C
O Each scale is configured as a server and shares the network ID with the other scales
on the network.
O Prices and products can be updated at any scale and replicated across the group.
O Floating vendor is allowed.
8.1.2 Network protocol

XM series scales’ network protocol and speed are as follows:
TCP/IP V4 protocol for both wired and wireless connections.
10/100 base T ethernet connection.
8.1.3 File sharing

Each XM scale will have its own copy of the database.
O Trading is from the local copy.
O Totals and transactions are stored locally.
O During totalisation, the scales are polled by the host/server and totals and transactions
are collected from all the scales in the network.
O If floating vendor is allowed, an open receipt will be copied from the scale to the host/
server collecting totals.

8.2 Network setup Communications
8.2 Network setup

The network settings are configured from within Manager Mode.
8.2.1 Network setup - wired

Scales are connected together using one or several hubs as required. The number and
position of the hubs required is determined by the store layout and the type of hub used.
Two scales can be connected together without the use of a hub. A simple cross cable is
used to connect the two machines together.
Each machine in a network must have a unique IP address. The IP address is used by the
TCP/IP protocol to identify the source and destination of data packets.
The machines are manufactured with unique IP addresses which only need to be
changed if the XM series network is to be integrated with an existing Ethernet network.
Note: Before setting up an in-store network, obtain the appropriate IP addresses from the
store IT administrator. Enter the addresses at the machines before connecting to the
network.
1. In Manager Mode select Comms Setup

2. Select Wired Setup
3. Ensure that DHCP Enable is set to 0. (Touch Edit to go to the editing screen.)
4. Set the IP address to one that is unique to that scale.
The IP address of the machine consists of two parts the network address and the
machine address.
O The network address
Important:The network address must be the same as all the other machines on the same
network.
O The machine address.
The machine address must be different from the other machines on the same
network
O Sub-net mask
The sub-net mask allows you to split a large physical network into smaller logical
networks.
O Gateway
Where XM series machines are linked to a PC through a gateway, the XM series
machine needs to know the gateway address in order to communicate with it.
DHCP networks
2. Select Wired Setup
3. Select DHCP Enable and set the value to 1. (Touch Edit to go to the editing screen.)

4. Set the IP address at each scale to 0.0.0.0. IP addresses will then be allocated by the
DHCP server for the network.
The host name enables the machine to be identified even if the IP address has changed.
The name can have up to 100 characters in either a fixed or variable string.
Cable lengths
The maximum cable length between each machine and the hub is one hundred metres.
Note: It is usual to allow 5m at either end for the patch cable from the scale to the wall
socket. This allows 90m for the cable run between network wall socket and patch panel.
If the connections between hubs use 10 base T connections, then there should be no
more than four hubs in series.
8.2.2 WLAN Network setup - RF comms (optional)

2. Select wireless setup
3. Select the field you wish to change (Touch Edit to go to the editing screen.)
Set the appropriate values for the type of wireless network.
O Set Mode to 0 for ‘Managed’ or 1 for ‘AdHoc’
‘Managed’ is for a communications system via an access point.
Use ‘Ad hoc’ for direct communication (peer to peer) networks.
O Set Channel to 0 for auto select on Managed Mode.
O ESSID
This is a 32 character alphanumeric string which separates wireless LANs. All
machines on the same WLAN must have matching ESSID.
Security settings
WEP
Key Mode
0 for WEP open
1 for WEP shared
2 for WEP auto detect
O Encryption type
1 for WEP
O Key type
Keys 1 to 4 can be configured as 0 for Hex or 1 for ASCII
WPA PSK
O Key Mode is 3 for WPA

O Encryption type is 2 for TKIP

O WPA PSK is the password
WPA2 PSK
O Key Mode is 4 for WPA2
O Encryption type is 3 for AES
O WPA PSK is the password

8.3 Network failure Communications
8.3 Network failure

If scales become disconnected from the network, the programmed network map is
changed to exclude offline machines. The background colour of the network icon in the
status bar of the offline scale changes to red.
Scales that are unable to communicate with the server are referred to as ‘Red’ machines.
Scales communicating with the server are referred to as ‘Green’.
The first time each operator uses the scale following a network failure an alert message
is displayed. There are three options:
O Cancel
O Retry
O Continue Anyway
If the operator chooses to continue trading (Continue Anyway) the Red machine will
operate in Local Mode and the scale will be unable to collect transactions and totals on
the rest of the network. The operator can still ‘float’ on Green machines.
The scale will display the message ‘Network Change. Check transaction’ when the
operator applies the first change to a transaction after a network map change.
8.3.1 Network reconciliation

When communication with the server is re-established item and transaction data is
resynchronised across the network using the most recent data.

Preventative maintenance
Preventative maintenance
This chapter contains information on maintenance schedules.
Contents
9
9.1, Checklist

9.1 Checklist Preventative maintenance
9.1 Checklist
Ref no. Checklist Check on ‘PM’

1 Ask the operator if they have noticed any problems
2 Are the serial number/contractual details correct
3 Are the verification seals in place?
4 Check general machine integrity including all display segments, front and back
5 Check the condition of external cables, (mains and communication) ensuring that they
are restrained where appropriate
6 Check internals for water damage, etc.
7 Check battery voltages where appropriate
8 Check that all internal looms are securely seated
9 Check basic keyboard functions (0-9 keys, zero, tare, print, etc.)
10 Is print quality high enough? – scan labels through checkouts where appropriate
11 Check scale is level and weighing correctly (including balance limit)
12 Check that customer has correct service contact numbers (independent customers only)
– new stickers should be applied if necessary
13 Check dot wear of the printer and replace if severely worn
14 Check the calibration of the touchscreen
15 Does the machine function correctly after maintenance?

Index
C gravity settings 22
keyboard overlay 19, 26
Cable management
XM100 17 levelling 26
XM600 17 location 16
connections print head cleaning 28
external 16 printer setup 22
RF device 20
scale cleaning 29
E touch screen calibration 23
External connections 70 USB devices 20
peripherals 70 warm start 25
Schematics
loadcell, display and keyboard 74
I power and printer 71
Imaging utility 86 Service mode
cold start 62
configuration data 63
L entering and exiting 61
Label gap sensor 39 service setup 68
Loadcell connections 78 warm start 62
Service procedures
column assembly 51
M customer display assembly 52
Memory 89 customer display assembly (XM200 & XM400)
Modules 53
LVDS and logo 81 inclinometer 49
mainboard 79 loadcell 48
power supply unit 82 power supply unit 47
printer controller 80 printer controller PCB 40
rear housing 50
N removing front and left side cover 57
removing the display 54
Networks 92 removing the front bezel 41
failure 97
removing the keyboard 44
file sharing 93
removing the main board 41
multi-server 92
removing the operator display 44
peer groups 93
removing the print head 34
scale 92
removing the printer chassis 35
server/client 92
removing the speaker 45
wired setup 94
removing weigh plate, top and cover. 33
WLAN 95
service switch 49
tools 32
P Software update
USB interface 84
Printer roller 37, 38
S X
Safety 8 XM series models
XM100 13
handling 8
XM200 13
service precautions 9
XM400 13
Scale installation
calibration 21 XM600 14
cold start 25 A
front bezel adjustment 19

Foundry Lane,
Smethwick, West Midlands,
England B66 2LP
Tel: +44 (0)870 903 2000
Fax: +44 (0)870 904 2223
Email: info@averyberkel.com
Internet:: www.averyberkel.com

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XM Series

Counter Service Scales

ABR35-000511-AA *AWT35-000511* 26-05-2010

XM series Service Instructions 3

6 Schematics and Wiring

4 XM series Service Instructions

XM series Service Instructions 5

XM series Service Instructions 7

1.1 Installation and service

1.1.1 Safe handling

1.1.2 ESD precautions

1.1.3 Electrical installation

1.1.4 Risk of electric shock

XM series Service Instructions 8

1.1.5 Service precaution

1.1.6 Replacing batteries

CAUTION: RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT

XM series Service Instructions 9

XM series Service Instructions 11

XM series Service Instructions 12

2.2 Scale configuration options

OCassette label/receipt printer in base

XM series Service Instructions 13

XM series Service Instructions 14

XM series Service Instructions 15

3.1 Connections and power up/down

Figure 3.1 Typical counter installations

XM series Service Instructions 16

3.2 Cable management

Cable clips are provided in the

Power supply lead clamping.

XM series Service Instructions 17

3.3 Fitting the XM200 angle display bracket

1.Remove the seal and screw

2.Slide the two covers up together

3.Fit the angle bracket in the

XM series Service Instructions 18

3.4 Front bezel

1.To raise the front bezel assembly,

2.To lower the front bezel, press

Inserting the programmable keyboard overlay.

1.Open the keyboard overlay

XM series Service Instructions 19

3.5 Peripheral devices

Dedicated USB connection for

3.5.2 Other peripherals

XM series Service Instructions 20

1.Turn the cover plate latch to

2.Break the paper seal and

XM series Service Instructions 21

3.Press the service switch (use a

3.6.3 Gravity settings

XM series Service Instructions 22

3.6.5 Touchscreen calibration

XM series Service Instructions 23

XM series Service Instructions 24

3.7 Power up sequence

3.7.2 Cold start

XM series Service Instructions 25

3.8 Customer hand over

3.8.1 Levelling the scale

3.8.2 Changing the keyboard insert

1.Open the keyboard overlay

ABR35-000511-AA AWT35-000511 26-05-2010