KERN DBS User manual

KERN & Sohn GmbH
Ziegelei 1
D-72336 Balingen
Phone: +49-[0]7433- 9933-0
Fax: +49-[0]7433-9933-149
Internet: www.kern-sohn.com
Service manual
Electronic Moisture Analyzer
KERN DBS
Version 1.0
11/2012
GB
DBS-SH-e-1210

GB KERN DBS
Version 1.0 11/2012
Service Manual
Electronic Moisture Analyser
Contents
1. Operations for Adjustment.................................................................................5
1.1 Entering the Service Mode .............................................................................................. 5
1.2 Service Menu..................................................................................................................... 6
1.3 Service Mode Functions .................................................................................................. 10
2. Disassembling and Assembling the Balance ...................................................12
2.1 Precautions....................................................................................................................... 12
2.2 Removing the Case .......................................................................................................... 13
2.3 Replacing Components ................................................................................................... 16
2.3.1 Replacing the Thermal Fuses (S18)................................................................................... 16
2.3.2 Replacing the Main Board Assembly (B2).......................................................................... 16
2.3.3 Replacing the Analog Board Assembly (B3) ...................................................................... 17
2.3.4 Replacing the Power Board Assembly (B4) ....................................................................... 19
2.3.5 Replacing the Inlet Assembly (S11) ................................................................................... 20
2.3.6 Replacing the DBS Unit Assembly (U1) ............................................................................. 21
2.3.7 Replacing the Detector Assembly (U11) ............................................................................ 23
2.3.8 Replacing the Force Coil Assembly (L1) ............................................................................ 24
2.3.9 Replacing the Sensor shaft (U4) ........................................................................................ 27
2.3.10 Replacing the Glass Unit Assembly (S3) ........................................................................... 27
2.3.11 Replacing the Windows Panel (C7).................................................................................... 27
2.3.12 Replacing the Top Case Grille (H2) ................................................................................... 28
2.3.13 Replacing the DBS Heater (S5).......................................................................................... 29
2.3.14 Replacing the Reflector Plate (H9)..................................................................................... 29
2.3.15 Replacing the Fan Cable Assembly (C5) ........................................................................... 30
2.3.16 Replacing the LSW Cable Assembly (C6).......................................................................... 31
2.3.17 Replacing the Right Hinge (H13), Left Hinge (H14), and Hinge Springs (H15) ................. 32
2.3.18 Replacing the Thermistor (H10) ......................................................................................... 34
2.3.19 Replacing the Thermal Fuse (H6) ...................................................................................... 36
2.3.20 Replacing the level Gauge Assy (B7)................................................................................. 37
3. Cheking the Eledctronic Board..........................................................................38
3.1 Main Board Assembly (B2).............................................................................................. 38
3.2 Analog Board Assembly (B3).......................................................................................... 38
3.3 Power Board Assembly (B4) ........................................................................................... 39
4. Hardware Adjustment.........................................................................................41
4.1 Adjusting the Detector Assembly (U11) Height............................................................. 42
4.2 Adjusting the Tilt Error .................................................................................................... 43
4.3 Adjusting the Cornerload Error....................................................................................... 44
2 DBS-SH-e-1210

5. Software Adjustment ..........................................................................................45
5.1 EPROM initialization ........................................................................................................... 45
5.2 Model Selection................................................................................................................... 45
5.2.1 How to specify the serial No without using a computer ........................................................ 46
5.3 Factory Settings (voltage/USB) ......................................................................................... 47
5.4 Switching ON and OFF the Setting Information Lock..................................................... 47
5.4.1 Unlocking the Setting Information ......................................................................................... 47
5.4.2 Locking the Setting Information............................................................................................. 47
5.5 Adjusting Linearity.............................................................................................................. 48
5.5.1 Weight Value input ................................................................................................................ 48
5.6 Span Calibration.................................................................................................................. 48
5.7 Temperature Calibration (Service Mode).......................................................................... 49
5.8 Temperature Calibration (User Mode)............................................................................... 49
5.9 Heater Operating Time Count............................................................................................ 49
6. EEPROM...............................................................................................................50
6.1 PRINT Operations ............................................................................................................... 50
6.2 Data Edit (EDIT) Operations............................................................................................... 51
6.3 Backup (BKUP) Operations ............................................................................................... 52
6.4 Download (RESTR) Operations......................................................................................... 52
6.5 All Initialization (INIT) Operations ..................................................................................... 52
7. Performance Inspection .....................................................................................53
7.1 Repeatability........................................................................................................................ 53
7.2 Cornerload Error ................................................................................................................. 53
7.3 Instrument-to-Instrument Variability Inspection.............................................................. 53
7.4 Tilt Error ............................................................................................................................... 53
7.5 Temperature......................................................................................................................... 54
8. Troubleshooting..................................................................................................55
8.1 General Corrective Measures ............................................................................................ 55
8.2 Error Display........................................................................................................................ 58
9. Troubleshooting..................................................................................................59
9.1 Nothing Is Displayed........................................................................................................... 59
9.2 Reproducibility pf Weight Measurements Is Poor........................................................... 60
9.3 “OL” or “-OL” Is Displayed................................................................................................ 61
9.4 Lid Open/Close Status IS NOT Detected .......................................................................... 63
9.5 Heater Does Not Come ON................................................................................................. 64
9.6 Does Not Reach Teperature Setting.................................................................................. 65
9.7 ERR. 124 Occurred.............................................................................................................. 66
10. Parts.....................................................................................................................67
10.1 DBS Exploded View ............................................................................................................ 67
10.2 DBS Maintenance Parts List .............................................................................................. 74
10.3 Tools..................................................................................................................................... 75
10.4 Optional accessories list.................................................................................................... 75
DBS-SH-e-1210 3

Basic information
Grundlegende Hinweise
The device must be repaired only by trained specialist staff or personnel
with professional formation (such as a repair-specialist accredited by law
concerning verification).
The service manual is obligatory for repair work.
After repair, original conditions of the device have to be restored.
Only original spare parts should be used.
Das Gerät darf nur von geschultem oder beruflich ausgebildetem Fachpersonal
(z. B. eichrechtlich anerkannter Instandsetzer) repariert werden.
Die Serviceanleitung ist bindend für Reparaturen.
Das Gerät muss nach erfolgter Reparatur wieder in den Originalzustand
zurückversetzt werden.
Es dürfen nur Originalersatzteile verwendet werden.
4 DBS-SH-e-1210

1. Operations for Adjustment
For the general operation method, refer to the User's Manual for the DBS.
1.1 Entering the Service Mode
Use the following procedure to switch from the user mode to the service mode.
(1) Hold down the [←] and [ESC] keys for at least 2 seconds. After
2 seconds, a buzzer sounds.
(2) Release the [←] and [ESC] keys.
(3) Within 1 second, hold down the [→] and [TARE] keys for 3 seconds.
(4) The password input display appears.
Use the arrow keys to enter numbers.
Enter 00321 as the maintenance mode password and press the [Enter]
key.
(5) When the password is approved, the service mode opens.
It is also possible to change from the user mode to the service mode by entering
the maintenance mode command "@SVC=321" into the computer
.
DBS-SH-e-1210 5

E o
L
o
g
D
s
p
a
E o
Log
D
sp
a
EoL
o
g
D
s
p
a
1.2 Se
r
v
ice Menu
The service mode configuration (menu configuration diagram) is shown below.
User
Mode
Password
Input
"321"
END
[
↑
]
r
r
r
(
l)
* [←] and [→] keys can
be
used
to
view 5
errors.
[
↓
]
[Normal Range (guideline)]
* Displays items
selected
in factory settings.
: [←][→]
:
[
↑
][
↓
]
: Next [ENTER]
Back [←]
: Next [ENTER]
(before aging)
* Display Example
*1) Loading pan(S14)( t0.3 Aluminum)
WG Display
LAD
Dis pl ay
OAD
Display
TAD
Dis play
WAD
Display
Zero
Drift Display
Zero
Drift Display
(after aging)
Zero(*1) Span (60 g)
WAD 300,000 to
800,000
Approx.
1,550,000
TAD ( 10 to 30
°
C) 26,000 to 40,000
OAD
±
10.000
(g)
Weighing
capacity (g)
LAD
WG
THAD
At TT = 25
°
C:
approx. 320 to 480
At TT = 100
°
C:
approx. 150 to 220
TT Room temperature
±
10
°
C
ST Room temperature
±
10
°
C
Span Temperature
Coefficient
Display
(before
aging)
Span
Te mp er a t ur e
Coefficient
Display
(after
aging)
Software Version Display
Span af ter aging 0 to
±
3.000 ppm/
°
C
Span before aging 0 to
±
10.000 ppm/
°
C
Zero after aging 0 to
±
0.002 g/
°
C
Zero before aging 0 to
±
0.015 g/
°
C
Only the most recent error is displayed.
Factory
Settings
Display
Model Name Display
Error
Log
Display (2)Error Log
Di splay
(1)
y
(5
i
l
y
(
1
)
E
r
r
o
r
Lo
g
r
r
s
r
r
r
i
r
l
y
p
la
y
(
3
)
4
)
i
Lights
up during service mode
Service Mode
External
Input
"@SVC=321"
DBS-SH-e-1210 6

*
Thermistor
AD
value
*
The rmi st or
temperature
*
Temp e r at u r e
on
pan
1
sec [ESC]
Execute
ENTER]
Enter
number
[ENTER]
(Enter calibration weight values and numerical
values)
(1)
Use the [←] and [→] keys to select the digit and then use the
[↑]
and
[↓]
keys to set the numerical
value.
(2)
Press [ENTER] to
confirm.
End
Span
Calibration
[ENTER]
Temperature
Calibration
[ENTER]
Note
1)
* 1D is minimum measurement
unit.
[ENTER]
Note
1)
[ENTER]
Cumulative
Count
Execute
[ENTER] End
Confirm
CLEAR
Zero-Tracking
1000D
10D
100D
1D
50D
0.5D
Set Stable Detection
Range
Te
m
pe
r
a
t
u
r
e
C
a
lib
r
a
t
ion
C
a
lib
r
a
t
ion
S
pan
C
a
li
b
r
a
t
i
on
Linea
r
i
t
y
A
djus
t
m
ent
Enter calibration
weight
value for
adjustment
Adjust
Linearit y
Confirm
"START"
[
ST
Dis play
TT
Display
THAD
Display
DBS-SH-e-1210 7

Note 1)
Enternumber
[ENTER] [ENTER]
Factory Settings 120 V, without USB
120 V, with USB
240 V, without USB
240 V, with USB
[ENTER]
Note 1)
Set OEM
[ENTER]
OK?
[ENTER]
L
oc
k
se
t
t
i
ng
i
n
f
o
r
ma
t
i
on
Note 1
)
(Not displayed if setting information lock is ON)
240V.U
Note 1
)
Set Bias
Factory Settings
Set OEM
Lock setting information
120V.
120V.U
240V.
240V.U
G
120V.
LOCK OFF
LOC K ON
DBS-SH-e-1210 8

Init
ialize All
"INIT"
* Abort with [ESC]
key.
Returns to "NVRAM" after output is
finished.
[Edit
Data]
(1)
Use [←] and [→] keys to move to changed location
(flashing).
(2)
Use
[↑]
and [↓] to set numerical values (0
t
o
F).
(3)
Use [ENTER] key
t
o confirm data
(fixed).
(4)
Use [ESC] to abort edit. Returns to "NVRAM" after "ABORT" is
displayed.
[ENTER]
Edit
Execute
[ENTER]
Note
2)
Execute
[ENTER]
Note
2)
Execute
[ENTER]
Note 2: Returns to "NVRAM" after execution is
finished.
Print Data
"PRINT"
[ENTER]
Error Log
Display
Note 1: Stability indicator lights up if the s etting is
ON.
Note 2: Returns to "NVRAM" after loading is
finished.
Use the arrow keys to move between items.
Key Description
→
Opens lower level menu.
←
Returns to higher level menu.
↓
Moves forward through items.
↑
Moves backward through items.
END
OK?
Init
ialize All
"INIT"
OK?
Download
"RESTR"
OK?
Backup
"BKUP"
Edit Data
"EDIT"
Print Data
"PRINT"
N
V
R
A
M
DBS-SH-e-1210 9

1.3. Service Mode Functions
Service mode functions are shown below.
Function Outline
Error display
Displays error codes for errors that have occurred in
the user mode.
If no errors have occurred when the service mode is
opened, the error display does not appear.
Model Name Display Displays the model name setting. (23 characters)
Software Version Display Displays the currently installed software version.
Span Temperature Coefficient Display Displays the span temperature coefficient before and
after aging.
Zero Drift Display Displays the amount of zero drift before and after
aging.
Mass Data (WAD) Display Displays mass data (smoothed) as received from the
AD converter.
Temperature Data (TAD)
Display
Digitally displays voltage from the temperature sensor
installed on UniBloc magnet or load cell.
Temperature-Corrected
Mass Data (OAD) Display
Displays temperature-corrected WAD mass data
(smoothed).
Linearity-Corrected Mass
Data (LAD) Display
Displays linearity-corrected OAD mass data.
Absolute Load (WG)
Display
Displays mass values corrected by all correction
processes in gram units. Displays mass values
unaltered by zero setting or tare subtraction.
Thermistor Temperature
(TH) Display
Digitally displays voltage (A/D value) from the
thermistor attached to the heater.
Thermistor Temperature
(TT) Display
Displays thermistor temperature (TT) values.
AD Value
Display
Pan-Top Temperature (ST)
Display
Displays pan-top temperature (ST) values.
Span Calibration Calibrates sensitivity using the same operations as in
the user mode.
Temperature Calibration
Calibrates temperature using the same operations as
in the user mode. (This function is used at the factory.
Use the temperature calibration function in the user
mode for normal calibration.)
Linearity Adjustment Makes adjustments for calculating linearity correction
coefficients.
Stable Detection Range Setting Function
Sets the stable detection range. Select from 0.5D, 1D,
10D, 100D, and 1000D. If the menu is reset, the range
is set to 1D.
Zero-Tracking Function Enables or disables zero-tracking.
Displays a cumulative count of the heater operating
Cumulative Count Display time.(1count=15minutes
)
Cumulative
Count Clear Cumulative Count Clears the cumulative time count of heater operation.
Bias Setting Function Sets the correction value for measurement values
(normally set to zero).
Factory Settings Specifies the voltage used and whether or not there is
an optional USB.
OEM Sets (or cancels) the OEM model.
10 DBS-SH-e-1210

when settings
a
r
e locked. Be su
r
e to lock setting
printer.
display unit.
linearity correction coefficient, and model setting status
memory.
Setting Information Lock
Disables changing model, OEM, factory, and serial
number settings.
The balance error check function is only enabled
information before handing over the system to the
cust
o
me
r
.
EEPROM
Print Data Outputs data stored in the EEPROM to the dedicated
Edit Data Edits data stored in the EEPROM using the balance
Backup
Backs up the temperature correction coefficient,
data stored in the EEPROM to flash memory.
Download Writes to the EEPROM the data backed up in flash
Initialize All Initializes all data saved in the EEPROM.
End Ends the service mode.
DBS-SH-e-1210 11

2.
Disassembling
and
A
ssembling
the Balance
2.1 P
r
ec
a
utions
1) Pull connectors straight out when disconnecting. Never pull them out at an angle.
* Pulling connect
o
r
s out
a
t
a
nanglec
o
uld bend the te
r
min
a
l
p
ins, m
a
king it difficult to
re-insert the connector.
Fig. 1
2) Before disassembling or assembling the MOC unit assembly (1) related parts, insert the lever
positioning pin (J1) into the lever fastener hole on the top of the OPF, up to the reference line.
Note: Insert the pin while slightly lifting up the lever assembly (U7). Be careful not to damage
the elastic support.
3) Use a controlled torque driver to tighten the screws to the torques shown in the table below.
(*1) 80 [cN•m] for only the sensor shaft
4) To retighten self-tapping screws, carefully align the threads so they are not damaged.
Note: Turn the screw counterclockwise until it drops back into the screw hole, and screw it in
to tighten.
Screw Torque [cN•m]
M2 10
M2.5 25
M3 pan head 90
M3 hexagonal socket
head bolt 150
M4 pan head 180
M4 hexagonal socket
head bolt 300 (*1)
12 DBS-SH-e-1210

2.2
R
emo
v
ing the Case
Dis
a
ssem
b
l
y
1) Remove the power cord from the moisture analyzer, open the heater cover, and remove the sample
pan(S14),the pan supporter assembly (S11), windbreak (S12), and heater insulation plate (S13)
(Fig. 1).
Remove the M3
×
8 flat head screws (S52) from the back of the balance (Fig. 2).2)
S
11
S
5
2
S12 S
5
2
S13
Fig. 1 Fig. 2
3) Remove the P4 M4
×
16 screws (S53) from the base plate, along with the grounding spring (S4),
slightly lift the back of the case assembly (S2), and then shift it forward to separate it from the base
(Fig. 3).
Place the case assembly (S2) behind the base not to be damaged on cushion.(Fig. 4).
4)
S
5
3S4
S2
S
5
3
S2
S2
Fig. 3 Fig. 4
DBS-SH-e-1210 13

5) Disconnect the four cables connected to the case assembly (S2) from J2,J3,J4 and J5 connector of
power board assembly (B4) (Fig. 5).
Remove the P4 M4
×
8 screw (S51) from the boss located to the side of the power board assembly
(B4) and remove the FG ground cable (H8) (Fig. 6).
Note: The main board assembly (B2) and power board assembly (B4) can be inspected in
this state.
6)
H8
S
5
1
Fig. 5 Fig.6
Assembl
y
1)
2)
Place the case assembly (S2) behind the base (Fig. 4).
Fasten the FG ground cable (H8) to the boss located to the side of the power board assembly (B4)
using the P4 M4
×
8 screw (S51) (Fig. 5).
Connect the four cables from the case assembly (S2) to J2,J3,J4 and J5 conncetor of the power
board assembly (B4) (Fig. 5).
Note: Route the thermistor cable(J3) bypressing it into the gap between the base (B1) wall
and the power board assembly (B4).
Note: Use clamps to route the thermistor(J3) and heater lines(J2) away from the power
supply line and power board assembly (B4).
Attach the case assembly (S2) to the base assembly (S1) by hooking it on the flange on the front of
the base assembly (S1), being careful not to pinch any wires between the case and base, and fasten
it with the M3
×
8 flat head screws (S52) on the back side of the balance (Fig. 7).
Fasten the P4 M4
×
16 base plate screws (S53), together with the grounding spring (S4)on right side,
to the case assembly (S2) (Fig. 3).
Install the heater insulation plate (S13), windbreak (S12) , pan supporter assembly (S11) and sample
pan(S14) n this order (Fig. 1).
3)
4)
5)
6)
B4
J3
J4
J5
J2
14 DBS-SH-e-1210

Fig. 7
7) Level the balance by turning the two level adjusters (B6) at the front of the balance so that the bubble
in the level gauge is centered.
Connect the power cord and confirm that the balance portion of the moisture analyzer functions
properly.
When the display stop “check” after pressing the power key,press “←”key and “ESC” key for 3
seconds at the same time to be the gram display.
8)
DBS-SH-e-1210 15

2.3
R
e
p
l
a
cing C
o
mponents
2.3.1.
R
e
p
l
a
cing the Therm
a
l Fuses
(
S18)
1) Remove the fuse holder by inserting a flat head screwdriver below inside the filter (B11) fuse holder
(Fig. 8).
Remove the two fuses (S18) from the fuse holder (Fig. 9).
Install two new fuses (S18) by reversing steps 1 and 2 above.
2)
3)
B11
S18
S18
Fig. 8
Fig. 9
2.3.2
R
e
p
l
a
cing the M
a
in Bo
a
r
dAssembl
y
(
B2)
1) Disassemble the balance down to the case assembly (S2) by following the procedure in 2.2
Removing the Case.
2) Remove the three P4 M4
×
8 screws (B53) that fasten the main board assembly (B2) (Fig. 10).
16 DBS-SH-e-1210

B
5
3
B2
B
5
3
B
5
3
Fig. 10
Disconnect the three cables from connectors J1, J2, and J4 on the main board assembly (B2)and
separate from base assembly.
Remove the two EEMPROM from its socket on the back of the main board assembly (B2), being
careful not to damage its pins.
3)
4)
M4: Moisuture analyzer’s memory function M5: Balance’s fixed information
5)
6)
Install the EEPROM on the same place of the new main board assembly (B2).
Install the new main board assembly (B2) by reversing steps 2 to 6 above.
N
o
te: When assembling, inst
a
ll the m
a
in b
o
a
r
d ass
y
(B2) setting f
r
o
nt side
o
f
the base assy(B1)
2.3.
3
R
e
p
l
a
cing the An
a
l
o
gBo
a
r
d Assem
b
l
y
(
B3)
1) Disassemble the balance down to the main board assembly (B2), in the same manner as described
in 2.3.2. Replacing the Main Board Assembly (B2), steps 1 to 3.
Disconnect the three cables from connectors J1, J2, and J3 on the analog board assembly (B3),
loosen the four P4 M4
×
8 screws (53)and then remove the analog board cover plate (B14) (Fig. 11).
Loosen and remove the two P4 M4
×
8 screws (B22) that fasten the analog board assembly (B3)
(
Fi
g
. 12
)
.
2)
3)
B
5
3
B22
B
5
3
B
5
3B
5
3B22 B3
B14
Fig. 11 Fig. 12
4) Install a new analog board assembly (B3) by reversing steps 2 and 3 above.
Note: When assembling, install the analog board assy(B3) setting front side of
the base assy(B1) (Fig.12)
N
o
te: When assemblin
g
,use cli
p
CS-5
(
B2
6
)
to secu
r
el
y
hold the
po
we
r
bo
a
r
d assembl
y
(
B
4
)
DBS-SH-e-1210 17

c
a
ble d
o
wnt
o
w
a
r
d the b
o
ttom
(
Fig. 13).
B26
Fig. 13
18 DBS-SH-e-1210

2.3.
4
R
e
p
l
a
cing the P
o
we
r
Bo
a
r
d Assembl
y
(
B
4
)
1) Disassemble the balance down to the case assembly (S2) by following the procedure in 2.2
Removing the case.
Loosen the two M3
×
6 bind screws (B55) (Fig. 14).
Remove the two D-sub screws (B25) that fasten the power board assembly (B4) and rear panel (B5),
and remove the rear panel (Fig. 15).
2)
3)
B
5
5B25
B25
B
5
5B5
Fig. 14 Fig. 15
4)
5)
Disconnect J1l cables connected to the power board assembly (B4) (Fig. 16).
Loosen the four P4 M4
×
8 screws (B53) that fasten the power board assembly (B4), and remove the
board along with clip CS-5 (B26) (Fig. 16).
Note: The power board assembly (B4) can be removed by lifting it up at an angle, as shown
in Fig. 17.
Disconnect J9 and J10 cables connected to the power board assembly (B4) (Fig.17)
6)
B
5
3B4
B
5
3
B
5
3B
5
3
B4
Fig. 16 Fig. 17
J1
J10
J9
DBS-SH-e-1210 19

7) Install a new power board assembly (B4) by reversing steps 1 to 5 above.
N
o
te: When assembling, use clip CS-5
(
B2
6
) to secu
r
el
y
hold the p
o
we
r
bo
a
r
d assembl
y
(
B
4
)
cable down toward the bottom (Fig. 18).
Note: When assembling, tighten screws of procedure 5 temporally and tighten firm after
ti
g
htenin
g
sc
r
ew
o
f
p
r
ocedu
r
e2and3.
B26
B4
Fig. 18
2.3.
5
R
e
p
l
a
cing the Inlet
A
ssembl
y
(
S11)
1) Disassemble the balance down to the case assembly (S2) by following the procedure in 2.2
Removing the case.
Loosen the two screws,pan head M3x8(B52) that fasten the inlet assembly(S11).(Fig.19)
Disconnect the cables connected to the J1 connector of the power board assembly(B4),(Fig.20)
Loosen the screw P4 M4x8(B53)(Fig.20)
Remove the inlet assembly(S11) from rear side of the base assembly(B2)
Install a new inlet assembly (S11) by reversing steps 1 and 5 above.
2)
3)
4)
5)
6)
N
o
te: When assembling, inst
a
ll the inlet
a
ssem
b
l
y
(S11)
p
r
inted face t
o
p.
(
Fig.19, 20)
Note: When assembling, align the cables of the inlet assembly (S11) as shown. (Fig.20)
B4
S
11
B
5
2
B
5
2
S
11 B
5
3
Fig.19 Fig.20
J1
20 DBS-SH-e-1210
This manual suits for next models
1
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