OHAUS Adventurer Pro Balances User manual

SERVICE MANUAL
ADVENTURERPRO BALANCES
and
ADVENTURER SL BALANCES
99 Washington Street
Melrose, MA 02176
Phone [phone]
Toll Free 1-800-517-8431
Visit us at www.TestEquipmentDepot.com

SERVICE MANUAL
ADVENTURER PRO BALANCES
and
ADVENTURER SL BALANCES
The information contained in this manual is believed to be accurate at the time of publication, but Ohaus
Corporation assumes no liability arising from the use or misuse of this material. Reproduction of this
material is strictly prohibited.
Material in this manual is subject to change.
© Copyright 2005 Ohaus Corporation, all rights reserved.
TM Registered trademark of Ohaus Corporation.

i
TABLE OF CONTENTS
CHAPTER 1 INTRODUCTION
1.1 Introduction .............................................................................................................1-1
1.2 Service Facilities.....................................................................................................1-1
1.3 Tools and Test Equipment Required.......................................................................1-2
1.3.1 Special Tools and Test Equipment List .............................................................1-2
1.3.2 Standard Tools and Test Equipment List...........................................................1-2
1.4 Test Masses Required ............................................................................................1-3
1.5 Specifications..........................................................................................................1-5
CHAPTER 2 DIAGNOSIS
2.1 Troubleshooting ......................................................................................................2-1
2.2 Diagnostic Guide.....................................................................................................2-1
2.2.1 Diagnosis...........................................................................................................2-1
2.3 Error Codes for all Models.......................................................................................2-7
CHAPTER 3 REPAIR PROCEDURES
3.1 Repair Procedures Small Frame AS AND AV Models ............................................3-1
3.1.1 Opening the Balance .........................................................................................3-1
3.1.2 Display Circuit Board Repair or Replacement ...................................................3-3
3.1.3 Main Printed Circuit Board Replacement...........................................................3-5
3.1.4 RS232 Interface Printed Circuit Board Replacement (AV Models only).............3-6
3.1.5 Strain Gauge Load Cell Replacement ...............................................................3-7
3.2 Repair Procedures Large Frame AS and AV Models..............................................3-8
3.2.1 Opening the Balance .........................................................................................3-8
3.2.2 Display Circuit Board Repair or Replacement .................................................3-11
3.2.3 Main Printed Circuit Board Replacement.........................................................3-12
3.2.4 RS232 Interface COM 1 or (COM 2 RS or USB) Printed Circuit Board
Replacement ...................................................................................................3-13
3.2.5 Strain Gauge Load Cell Replacement with InCal ...........................................3-14
3.2.6 Strain Gauge Calibration InCal Mechanism Removal/Replacement ...............3-15
3.2.7 Load Cell (MFR) Replacement ........................................................................3-18
3.2.8 InCal Motor Removal/Replacement ................................................................3-20
3.2.9 InCal Mechanism Removal/Replacement........................................................3-22
3.2.10 Position Sensor Assembly Removal/Replacement .........................................3-24
3.2.11 Unmounting the Load Cell from the Base Plate ...............................................3-25
3.2.12 Changing the Load Cell Board ........................................................................3-26
3.2.13 Removing the Ratio Beam...............................................................................3-28
3.2.14 Installing the Ratio Beam.................................................................................3-34
3.2.15 Vertical Stop Adjustment..................................................................................3-37
Page No.

ii
TABLE OF CONTENTS (Cont.)
CHAPTER 4 TESTING
4.1 Testing ....................................................................................................................4-1
4.1.1 Operation Test ...................................................................................................4-1
4.1.2 AV Models Segment Display Test .....................................................................4-1
4.1.3 AS Models Segment Display Test .....................................................................4-1
4.2 AV and AS Models Strain Gauge Performance Tests .............................................4-2
4.2.1 Repeatability Test..............................................................................................4-3
4.2.2 Off-CenterLoadTest..........................................................................................4-3
4.2.3 Linearity Test .....................................................................................................4-4
4.2.4 Load Cell Adjustments (Strain Gauge Models Only)..........................................4-5
4.3 MFR Load Cell Performance Tests .........................................................................4-8
4.3.1 Repeatability Test..............................................................................................4-8
4.3.2 Checking the Off-Center Load ...........................................................................4-8
4.3.3 Linearity Test .....................................................................................................4-9
4.3.4 Adjusting the MFR Load Cell Off-Center Load...................................................4-9
4.4 RS232 Interface Test AV Models Only..................................................................4-11
4.4.1 Connecting the RS232 Interface......................................................................4-11
4.4.2 Communication................................................................................................4-13
4.4.3 Commands ......................................................................................................4-13
4.5 Print Test...............................................................................................................4-14
4.6 Testing the AC Adapter .........................................................................................4-15
4.7 InCal Motor Testing ...............................................................................................4-15
CHAPTER 5 DRAWINGS AND PARTS LISTS
5.1 Drawings.................................................................................................................5-1
5.2 Parts Lists................................................................................................................5-3
APPENDIX A STANDARD CALIBRATION
A.1 Span Calibration .................................................................................................... A-1
A.2 Linearity Calibration ............................................................................................... A-1
APPENDIX B SERVICE CALIBRATION
B.1 Navigation.............................................................................................................. B-1
B.2 Entering the Service Menu ..................................................................................... B-1
B.3 Ramp ..................................................................................................................... B-1
B.4 Linearity Calibration ............................................................................................... B-2
B.5 Span Calibration .................................................................................................... B-2
APPENDIX C ADVENTURER PRO SERVICE TOOL INSTRUCTIONS
C. Software Service Tool Instructions ......................................................................... C-1
C.1 To Restore EEPROM Data .................................................................................... C-2
C.2 To Replace a Loadcell ........................................................................................... C-3
C.3 To Update Software in the Balance........................................................................ C-4
Page No.

iii
LIST OF TABLES
TABLE NO. TITLE Page No.
1-1 Adventurer AV Models Calibration Points ............................................................1-3
1-2 Adventurer AS Models Calibration Points ............................................................1-4
1-3 Adventurer AV Model Specifications ....................................................................1-5
1-4 Adventurer AS Model Specifications ....................................................................1-6
2-1 Balance Will Not Turn On with AC Adapter (All Models) ......................................2-2
2-2 Balance Will Not Turn On Using Batteries............................................................2-2
2-3 Balance Does Not Respond to Front Panel Controls ...........................................2-4
2-4 No Display or Partial Display ...............................................................................2-4
2-5 Balance Cannot Calibrate Manually.....................................................................2-5
2-6 Balance Cannot Calibrate Internally - AV Models Only ........................................2-6
2-7 Error Codes ..........................................................................................................2-7
4-1 AV Performance Test Tolerances.........................................................................4-2
4-2 AS Performance Test Tolerances.........................................................................4-2
4-3 AV Models Test Masses.......................................................................................4-4
4-4 AS Models Test Masses.......................................................................................4-4
4-5 AV Models Test Mass Values...............................................................................4-6
4-6 AS Models Test Mass Values...............................................................................4-6
4-7 AV Models Load Cell Up Stop Adjustment Tolerances ........................................4-6
4-8 AS Models Load Cell Up Stop Adjustment Tolerance..........................................4-7
4-9 AV Models Test Masses.......................................................................................4-9
4-10 COM 1 Interface Pin Connections ......................................................................4-12
4-11 COM 2 Interface Pin Connections ......................................................................4-12
4-12 RS232 Command table ......................................................................................4-13
5-1 Replacement Parts List for AV and AS Small Frame Models ...............................5-3
5-2 Replacement Parts List for AV and AS Large Frame Models .............................5-10
LIST OF ILLUSTRATIONS
FIGURE TITLE Page No.
3-1 Top of Balance .....................................................................................................3-2
3-2 Bottom of Balance ................................................................................................3-3
3-3 Balance Opened...................................................................................................3-4
3-4 Removing Main PC Board....................................................................................3-5
3-5 Removing RS232 PC Board ................................................................................3-6
3-6 Removing Load Cell.............................................................................................3-7
3-7 Top of AV Balances..............................................................................................3-9
3-8 Top of AS Balances............................................................................................3-10
3-9 Large Frame Balance Opened ...........................................................................3-11
3-10 Removing Main PC Board..................................................................................3-12
3-11 Removing RS232 PC Board ..............................................................................3-13

iv
LIST OF ILLUSTRATIONS (Cont.)
FIGURE TITLE Page No.
3-12 Removing Strain Gauge Load Cell.....................................................................3-14
3-13 InCal Mechanism Identification...........................................................................3-15
3-14 Motor Mounting Screws Location .......................................................................3-15
3-15 Disengauge Timing Belt.....................................................................................3-16
3-16 Removing Top Gear ...........................................................................................3-16
3-17 Top Gear Removed ............................................................................................3-16
3-18 Top Gear Alignment ...........................................................................................3-16
3-19 Motor Installation ................................................................................................3-17
3-20 Motor Coupler Position.......................................................................................3-17
3-21 Coupler Shaft Rotation .......................................................................................3-17
3-22 MFR Load Cell Components..............................................................................3-18
3-23 Removing MFR Load Cell..................................................................................3-19
3-24 InCal Motor Location ..........................................................................................3-20
3-25 InCal Motor Removal..........................................................................................3-20
3-26 Checking Shaft Rotation on InCal Mechanism ...................................................3-21
3-27 Motor Coupler.....................................................................................................3-21
3-28 Motor Shaft in CCW Position..............................................................................3-21
3-29 Motor Shaft in CW Position.................................................................................3-21
3-30 InCal Mechanism Mounting Screws ...................................................................3-22
3-31 Removing InCal Mechanism ..............................................................................3-22
3-32 InCal Mechanism Alignment...............................................................................3-23
3-33 Centering InCal Weight ......................................................................................3-23
3-34 Removing Position Sensor Assembly ................................................................3-24
3-35 Ratio Beam Alignment........................................................................................3-24
3-36 Base plate Removal ...........................................................................................3-25
3-37 Load Cell Mounting Components .......................................................................3-25
3-38 Load Cell Alignment to Base Plate.....................................................................3-26
3-39 Temperature Sensor Board Unsoldering Location .............................................3-26
3-40 Load Cell PC Board Item Locations ...................................................................3-27
3-41 Load Cell PC Board Removed from Load Cell...................................................3-27
3-42 Contact Board Location ......................................................................................3-28
3-43 Close-Up of Mounting.........................................................................................3-28
3-44 Ratio Beam and Weight Arm Components.........................................................3-28
3-45 Centering Pins Installation..................................................................................3-29
3-46 Loosening Ratio Beam Nuts...............................................................................3-29
3-47 Ratio Beam Screws and Washers Removed......................................................3-30
3-48 Loosening InCal Weight Arm Nuts .....................................................................3-30
3-49 InCal Weight Arm Screws and Washers Removed ............................................3-31
3-50 InCal Weight Arm Removal ................................................................................3-31
3-51 InCal weight Arm Removed................................................................................3-31
3-52 Aluminum Sleeves Removed .............................................................................3-32
3-53 Centering Pins Removed ...................................................................................3-32
3-54 Vertical Adjustment Screw Positioning...............................................................3-32

v
LIST OF ILLUSTRATIONS (Cont.)
FIGURE TITLE Page No.
3-55 Removing the Ratio Beam..................................................................................3-33
3-56 Removing the Aluminum Sleeves ......................................................................3-33
3-57 Ratio Beam Weight Removed ............................................................................3-34
3-58 Load Cell Critical Area .......................................................................................3-34
3-59 Load Cell Magnet Area.......................................................................................3-35
3-60 Ratio Beam vane Slotted Area ...........................................................................3-35
3-61 Adjusting Screw Alignment ................................................................................3-36
3-62 Repositioning the Contact Board and Screw......................................................3-36
3-63 Test Connector Location ....................................................................................3-37
3-64 Area of Detail......................................................................................................3-37
4-1 LCD Full Display for Models AV...........................................................................4-1
4-2 LCD Full Display for Models AS...........................................................................4-1
4-3 Load Cell End View - Adjustments .......................................................................4-5
4-4 Off-CenterLoad ....................................................................................................4-8
4-5 MFR Adjustments...............................................................................................4-10
4-6 COM 1 Connector...............................................................................................4-12
4-7 COM 2 MINI DIN Connector ...............................................................................4-12
4-8 COM 2 USB Type B Connector..........................................................................4-12
4-9 Motor Wiring Diagram.........................................................................................4-16
5-1 Adventurer AS and Av Models, Small Frames, Exploded View............................5-2
5-2 Adventurer AS and AV Models, Large Frams, Exploded View.............................5-9
B.1 Sevice Mode Menu.............................................................................................. B-1

vi