OHAUS Pioneer PA64 User manual

SERVICE MANUAL
Ohaus Corporation 19A Chapin Road, P.O. Box 2033, Pine Brook, NJ 07058-2033 [phone]

TABLE OF CONTENTS
Ohaus Corporation www.ohaus.com i Pioneer™ Balances Service Manual
Page No.
CHAPTER 1 GETTING STARTED
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....................................................................................................1-2
1.3.2 Standard Tools and Test Equipment.................................................................1-2
1.4 Specifications...........................................................................................................1-2
1.5 Balance Operation ...................................................................................................1-5
1.5.1 Overview of the Controls...................................................................................1-5
1.5.2 Overview of the Display Indicators....................................................................1-6
1.5.3 Power On..........................................................................................................1-7
1.5.4 Power Off..........................................................................................................1-7
1.5.5 Menu Setup ......................................................................................................1-7
1.5.6 Menu Structure.................................................................................................1-7
1.5.7 The Load Cell ...................................................................................................1-8
1.6 Connecting the RS232 Interface ..............................................................................1-9
1.7 RS232 Commands.................................................................................................1-10
CHAPTER 2 TROUBLESHOOTING
2.1 Troubleshooting.......................................................................................................2-1
2.1.1 General Procedures for Troubleshooting ..........................................................2-1
2.2 Diagnostic Guide......................................................................................................2-1
2.2.1 Diagnosis..........................................................................................................2-1
2.3 Error Codes..............................................................................................................2-4
CHAPTER 3 MAINTENANCE PROCEDURES
3.1 Preventive Maintenance...........................................................................................3-1
3.1.1 Preventive Maintenance Checklist....................................................................3-1
3.2 Opening the Balance................................................................................................3-1
3.2.1 Variations in Opening Pioneer Models..............................................................3-2
3.3 Load Cell Removal and Disassembly.......................................................................3-3
3.3.1 Variations in Pioneer Load Cells.......................................................................3-3
3.3.2 Disassembly of Precision Balances with Internal Calibration.............................3-4
3.3.3 Removing Internal Calibration Weights.............................................................3-5
3.3.4 Servicing the Internal Calibration Mechanism ...................................................3-5
3.3.5 Reassembling the Internal Calibration Mechanism............................................3-6
3.3.6 Disassembly of Precision Balances with InCal Mechanism...............................3-6
3.3.7 Removing the Load Cell –Precision Balances..................................................3-7
3.3.8 Load Cell Disassembly –Precision Balances....................................................3-8
3.3.9 Position Sensor Board Removal/Replacement/Adjustment –Precision...........3-13
3.3.10 Main Printed Circuit Board (PCB) Replacement –All Balances.......................3-14
3.3.11 Load Cell Reassembly –Precision Balances..................................................3-15
3.3.12 Removing the InCal Mechanism from InCal Analytical Balances.....................3-19
3.3.13 Removing Internal Calibration Weights and Components ...............................3-19
3.3.14 Re-Installing Internal Calibration Components................................................3-21
3.3.15 Load Cell Removal/Installation –Analytical Balances.....................................3-21
3.3.16 Disassembling Analytical Load Cells...............................................................3-22
3.3.17 Position Sensor PC Board Removal/Replacement/Adjustment - Analytical.....3-28
3.3.18 Reassembling Analytical Load Cells ...............................................................3-29
3.3.19 Block Style Load Cell Removal & Replacement..............................................3-34

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3.3.20 Block Style Load Cell Disassembly & Replacement with Load Cell Kit............3-35
3.3.21 Progressive Disassembly of Block Style Load Cells........................................3-35
3.3.22 Internal Calibration Testing.............................................................................3-36
3.3.23 InCal Motor Removal & Replacement.............................................................3-36
3.3.24 InCal Mechanism Removal .............................................................................3-37
3.3.25 InCal Mechanism Installation ..........................................................................3-38
3.3.26 Position Sensor Assembly Removal/Installation on MFR Load Cell ................3-39
3.3.27 Removing the Block Style Load Cell from the Base Plate ...............................3-40
3.3.28 Installing the Block Style Load Cell on the Base Plate ....................................3-41
3.3.29 Removal and Installation of the Block Style Load Cell PC Board ....................3-42
3.3.30 Removing the Ratio Beam on Block Style Load Cells.....................................3-43
3.3.31 Installing the Ratio Beam on Block Style Load Cells.......................................3-47
3.3.32 Installing the InCal Weight Arm.......................................................................3-49
3.3.33 Installing the Load Cell PCB-Temperature Sensor-Position Sensor................3-51
3.2.34 Setting the Up/Down Stop Screw on Block Style Load Cells...........................3-53
CHAPTER 4 TESTING
4.1. Testing.....................................................................................................................4-1
4.1.1 Test Masses Required......................................................................................4-2
4.2 Operational Test ......................................................................................................4-1
4.3 Segment Display Test..............................................................................................4-1
4.4. Performance Tests...................................................................................................4-2
4.4.1 Precision Test...................................................................................................4-2
4.4.2 Off-Center Load Test........................................................................................4-3
4.4.3 Off-Center Load Adjustment for Precision Models.............................................4-4
4.4.4 Off-Center Load Adjustment for Analytical Models............................................4-5
4.4.5 Off-Center Load Adjustment for Block Style Models..........................................4-6
4.4.6 Repeatability Test.............................................................................................4-7
4.4.7 Linearity Test....................................................................................................4-9
CHAPTER 5 DRAWINGS AND PARTS LISTS
5-1 Precision Top Load Balance Housing & Internal Parts.............................................5-2
5-2 Round Pan Block Style InCal Balance: Housing & Internal Parts .............................5-4
5-3 Square Pan Block Style Square Pan Balance: Housing & Internal Parts..................5-6
5.4 Precision Draft Shield Balance with Draft Shield: Housing & Parts...........................5-8
5.5 Analytical Balance: Housing & Internal Parts..........................................................5-10
5.6 Precision Balance Load Cell & Parts......................................................................5-12
5.7 Analytical Balance Load Cell & Parts.....................................................................5-14
5.8 Block Style InCal Load Cell & Parts .......................................................................5-26
Appendix A STANDARD CALIBRATION
A.1 Calibration...............................................................................................................A-1
A.1.1 Calibration Masses ..........................................................................................A-1
A.2 Span Calibration .....................................................................................................A-1
A.3 Linearity Calibration ................................................................................................A-2
Appendix B SERVICE CALIBRATION
B.1 Entering the Service Menu......................................................................................B-1
B.2 Ramp......................................................................................................................B-1
B.3 Service Span Calibration.........................................................................................B-2
B.4 Service 3 Point- Linearity Calibration ......................................................................B-3

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B.5 Service 5 Point- Linearity Calibration …………………………………………………...B-4
Page No.
LIST OF TABLES
TABLE NO. TITLE Page No.
1-1 Specifications: External Calibration Models (includes M Models).........................1-2
1-2 Specifications: Internal Calibration Models (C & CM)...........................................1-3
1-3 Specifications: Carat Models ...............................................................................1-3
1-4 Specifications: Gold Models (External Calibration)...............................................1-4
1-5 Specifications: Gold Models (Internal Calibration)................................................1-4
1-6 Admissible Ambient Conditions............................................................................1-5
1-7 Functions of Display Controls ..............................................................................1-5
1-8 Display Indicators ................................................................................................1-6
1-9 COM 1 Interface Pin Connections........................................................................1-9
1-10 RS232 Command Table ....................................................................................1-10
2-1 Diagnostic Guide.................................................................................................2-2
2-2 Error Codes.........................................................................................................2-4
4-1 Test Masses Required.........................................................................................4-1
4-2 Tolerances –Precision Models............................................................................4-2
4-3 Tolerances –Analytical Models ...........................................................................4-2
4-4 Repeatability Worksheet......................................................................................4-8
5-1 Precision Top Load Balance Housing & Internal Parts.........................................5-3
5-2 Round Pan Block Style InCal Balance: Housing & Internal Parts.........................5-5
5-3 Square Pan Block Style Square Pan Balance: Housing & Internal Parts..............5-7
5.4 Precision Draft Shield Balance with Draft Shield: Housing & Parts ......................5-9
5.5 Analytical Balance: Housing & Internal Parts.....................................................5-11
5.6 Precision Balance Load Cell & Parts .................................................................5-13
5.7 Analytical Balance Load Cell & Parts.................................................................5-15
5.8 Block Style InCal Load Cell & Parts...................................................................5-17
LIST OF ILLUSTRATIONS
FIGURE NO. TITLE
1-1 Pioneer, Carat and Gold Series Displays.............................................................1-5
1-2 Pioneer Display Indicators...................................................................................1-6
1-3 Pioneer Menu Structure.......................................................................................1-7
1-4 Load Cell Assembly.............................................................................................1-8
1-5 COM 1 Connector................................................................................................1-9
1-6 Soldering points J1 and J2...................................................................................1-9
3-1 Top panel lifts up and slides out...........................................................................3-2
3-2 Groove in side panel’s base liner aligns with tab on Housing...............................3-2
3-3 Precision Load Cell with Incal..............................................................................3-3
3-4 Analytical Load Cell with Incal .............................................................................3-3
3-5 Precision Load Cell..............................................................................................3-3
3-6 Analytical Load Cell.............................................................................................3-3
3-7 Precision Block Style Load Cell with InCal...........................................................3-4
FIGURE NO. TITLE Page No.
3-8 Analytical Block Style Load Cell with InCal..........................................................3-4
3-9 Precision Balance with InCal Mechanism ............................................................3-4
3-10 InCal Weight Cover removed...............................................................................3-5
3-11 Bottom Housing with Load Cell, Weight Arms and Weights removed...................3-5
3-12 InCal Motor removed from its Housing.................................................................3-6

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3-13 Screws securing Weight Arm assembly...............................................................3-6
3-14 Proper manner to grasp Load Cell when removing Weight Arm assembly...........3-7
3-15 Cable connects to Position Sensor Board............................................................3-7
3-16 Access the 3 screws to release Precision balance Load Cell from top center......3-7
3-17 Service Fixture, screws and washers for 150g to 310g Precision balances .........3-8
3-18 Service Fixture, screws and washers for 510g to 4100g Precision balances........3-8
3-19 Precision Load Cell top........................................................................................3-8
3-20 Precision Load Cell bottom..................................................................................3-8
3-21 Precision Load Cell (150g to 310g) top, with Service Fixture attached.................3-9
3-22 Service Fixture for 510g to 4100g Precision Load Cell, attached to Hanger.........3-9
3-23 Bent Flexure........................................................................................................3-9
3-24 Position Sensor Board.......................................................................................3-10
3-25 Contact Board with ribbon cable........................................................................3-10
3-26 Fine wires connected to the Contact Board, and affixed to Ratio Beam.............3-10
3-27 Contact Board taped to Ratio Beam after removal from frame...........................3-11
3-28 Hanger...............................................................................................................3-10
3-29 Two screws secure Magnet Half........................................................................3-11
3-30 Sideways Motion Stop Plate..............................................................................3-11
3-31 Ratio Beam clearing stop on Up/Down Stop Screw as it is lifted out..................3-12
3-32 Magnets must be clean......................................................................................3-12
3-33 Position Sensor Board.......................................................................................3-13
3-34 Adjust position of Sensor Board until Err8.X does not appear............................3-13
3-35 Position Sensor Board.......................................................................................3-14
3-36 Installing Ratio Beam, clearing the Up/down Stop Screw...................................3-15
3-37 Precision Load Cell (150g to 310g) top, with Service Fixture attached...............3-15
3-38 Service Fixture for 510g to 4100g Precision Load Cell, attached to Hanger.......3-15
3-39 Sideways Motion Stop Plate..............................................................................3-16
3-40 Two screws secure Magnet Half........................................................................3-16
3-41 Contact Board....................................................................................................3-16
3-42 Solder points on Position Sensor Board.............................................................3-16
3-43 Precision Load Cell top......................................................................................3-17
3-44 Precision Load Cell bottom................................................................................3-17
3-45 Ratio Beam Flexures and Vertical Flexure.........................................................3-17
3-46 Insert the 3 screws to secure Precision Load Cell in Bottom Housing................3-17
3-47 When Position Sensor Board shows normal weight, tighten its screws..............3-18
3-48 Analytical Balance with InCal Mechanism..........................................................3-19
3-49 InCal Weight Covers removed...........................................................................3-19
3-50 Bottom Housing with Load Cell, Weight Arms and Weights removed.................3-20
3-51 InCal Motor removed from its assembly.............................................................3-20
3-52 InCal Motor Cam in correct position for reassembly...........................................3-20
3-53 Cable connects to the Position Sensor Board....................................................3-21
3-54 On Analytical balances, the 3 screws securing Load Cell are on bottom............3-21
3-55 Service Fixture, screws and shims for Analytical balances ................................3-22
3-56 Bottom Mounting Plate and Flexure Arms, Analytical balance’s Load Cell.........3-22
3-57 Top Mounting Plate and Flexure Arms, Analytical balance’s Load Cell ..............3-22
LIST OF ILLUSTRATIONS
FIGURE NO. TITLE Page No.
3-58 Screws removed from Bottom Mounting Plate inserted into the Hanger.............3-23
3-59 Shims are inserted between the Hanger and the Load Cell ...............................3-23
3-60 Analytical balance Load Cell with Top Bracket visible........................................3-23
3-61 Vertical Flexure and screws, Lock Plate, washers, and bushings, removed.......3-23

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3-62 Top Flexure Arm (Analytical). ............................................................................3-23
3-63 Bottom Flexure Arm (Analytical) ........................................................................3-23
3-64 Hanger with two screws.....................................................................................3-25
3-65 Service Fixture attached to the front of Load Cell after removing Hanger ..........3-25
3-66 The Vane is secured by two screws near the rear of the Load Cell....................3-25
3-67 The Vane removed............................................................................................3-25
3-68 Two solder points on PSB, and two screw holes for removing the board...........3-26
3-69 Contact Board with 3-wire ribbon cable soldered to it ........................................3-26
3-70 Four screws secure the Magnet Half to the Ratio Beam ....................................3-26
3-71 The Magnet Half, when removed, should be cleaned ........................................3-25
3-72 A screw connects the Contact Board to the Load Cell .......................................3-26
3-73 Use a smaller screw to temporarily fasten it to the Ratio Beam..........................3-26
3-74 The Sideways Motion Stop Plate and the black Up/Down Stop screw ...............3-27
3-75 Position Sensor Board (Analytical).....................................................................3-28
3-76 Adjust Position Sensor Board vertically until Err8.X does not appear.................3-28
3-77 The Ratio Beam needs to clear the groove in the Up/Down Stop Screw............3-29
3-78 Service Fixture is installed prior to installing Ratio Beam Flexures.....................3-29
3-79 Sideways Motion Stop Plate and Up/Down Stop Screw.....................................3-29
3-80 Elongated holes on Ratio Beam Flexures go on the bottom...............................3-29
3-81 Installing the Magnet Half ..................................................................................3-30
3-82 Four screws on Magnet Half..............................................................................3-30
3-83 Position Sensor Board.......................................................................................3-30
3-84 3-wire cable soldered to Contact Board.............................................................3-30
3-85 Installing the Vane.............................................................................................3-30
3-86 Screws removed from Bottom Mounting Plate inserted into the Hanger.............3-31
3-87 Insert shims between the Hanger and the Load Cell on both sides....................3-31
3-88 Bottom Flexure Arm...........................................................................................3-31
3-89 Top Flexure Arm................................................................................................3-31
3-90 Vertical Flexure..................................................................................................3-31
3-91 Vertical Flexure and screws, Lock Plate, washers, and bushings, removed.......3-31
3-92 Analytical InCal Load Cell with Top Bracket visible............................................3-32
3-93 Analytical balance Load Cell with Top Bracket visible........................................3-32
3-94 Bottom Mounting Plate on Analytical Load Cell..................................................3-32
3-95 Ribbon cable connects PSB to Main PCB..........................................................3-32
3-96 When Position Sensor Board shows normal weight, tighten its screws..............3-33
3-97 Block Style Load Cell.........................................................................................3-34
3-98 Service Toolset for Block Style Load Cells. PN 476000-030.............................3-35
3-99 InCal Motor........................................................................................................3-36
3-100 InCal Motor Removal.........................................................................................3-36
3-101 Motor Coupler....................................................................................................3-36
3-102 Motor Shaft in counter-clockwise position..........................................................3-37
3-103 Mounting Screws holding InCal Mechanism.......................................................3-37
3-104 Removing the InCal Mechanism........................................................................3-37
3-105 InCal Mechanism Alignment..............................................................................3-38
3-106 Centering InCal Weight......................................................................................3-38
LIST OF ILLUSTRATIONS
FIGURE NO. TITLE Page No.
3-107 Removing Position Sensor.................................................................................3-39
3-108 Ratio Beam Pin Alignment.................................................................................3-39
3-109 Base Plate Removal..........................................................................................3-40
3-110 Load Cell Mounting Components.......................................................................3-41

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3-111 Load Cell Alignment to Base Plate.....................................................................3-41
3-112 Block Style Load Cell PC Board Item Locations.................................................3-42
3-113 Block Style Load Cell PC Board Removed from Load Cell.................................3-42
3-114 Load Cell PCB-Temperature Sensor-Position Sensor assembly........................3-43
3-115 Position Sensor .................................................................................................3-43
3-116 Removing Temperature Sensor.........................................................................3-43
3-117 Load Cell PCB...................................................................................................3-44
3-118 Contact Board Cover is removed by squeezing the plastic post.........................3-44
3-119 Contact Board with cover holder off...................................................................3-44
3-120 Centering Pins...................................................................................................3-44
3-121 Centering Pins Installed.....................................................................................3-44
3-122 Contact Board Location.....................................................................................3-45
3-123 Contact Board with cover holder off...................................................................3-45
3-124 Loosening Ratio Beam Nuts..............................................................................3-45
3-125 Ratio Beam Screws and Washers removed.......................................................3-45
3-126 Loosening InCal Weight Arm nuts......................................................................3-46
3-127 Weight Arm Screws and Washers removed.......................................................3-46
3-128 InCal Weight Arm removal.................................................................................3-46
3-129 InCal Weight Arm removed................................................................................3-46
3-130 Aluminum Sleeves removed..............................................................................3-47
3-131 Up/Down Stop Screw.........................................................................................3-47
3-132 Centering Pins removed ....................................................................................3-47
3-133 Removing the Ratio Beam.................................................................................3-47
3-134 Ratio Beam Removed........................................................................................3-47
3-135 Removing the Ratio Beam.................................................................................3-47
3-136 Ratio Beam Removed........................................................................................3-47
3-137 Removing the Aluminum Sleeves......................................................................3-47
3-138 Ratio Beam Weight Removal.............................................................................3-48
3-139 Load Cell Critical Area.......................................................................................3-48
3-140 Magnet Area......................................................................................................3-48
3-141 Ratio Beam Vane Slotted Area..........................................................................3-49
3-142 Four Ratio Beam sleeves are larger than the four Weight Arm sleeves .............3-49
3-143 Replacing the Ratio Beam.................................................................................3-49
3-144 Positioning the Ratio Beam over the Magnet.....................................................3-49
3-145 Centering Pin goes into first hole after upward bend in Ratio Beam...................3-49
3-146 InCal Weight Arm before insertion.....................................................................3-50
3-147 Inserting InCal Weight Arm................................................................................3-50
3-148 Weight Arm must be lifted slightly to insert Centering Pin..................................3-50
3-149 Proper method for tightening nuts while holding screw head stationary.............3-50
3-150 Centering pins in Ratio Beam ............................................................................3-51
3-151 Tightening Ratio Beam nuts...............................................................................3-51
3-152 Up/Down Stop Screw.........................................................................................3-51
3-153 Repositioning the Contact Board and Screw......................................................3-51
3-154 Load Cell PCB, Temperature Sensor and Position Sensor................................3-52
3-155 Groove on left of PCB fits tab on Load Cell frame..............................................3-52
LIST OF ILLUSTRATIONS
FIGURE NO. TITLE Page No.
3-156 Temperature Sensor extends into a hole in the Magnet.....................................3-52
3-157 Position Sensor on the Magnet..........................................................................3-53
3-158 Pin centered in PSB...........................................................................................3-53
3-159 Load Cell PCB Test Connector..........................................................................3-54

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3-160 Test Connector Detail........................................................................................3-54
3-161 Up/Down Stop Screw.........................................................................................3-54
4-1 Segment Display .................................................................................................4-1
4-2 Mass Placement Locations for Off-Center Load Test...........................................4-3
4-3 Off-Center Load Adjustment Screws on Analytical models ..................................4-4
4-4 Off-Center Load Adjustment Screws on Precision models...................................4-4
4-5 Off-Center Load Adjustments ..............................................................................4-4
5-1 Precision Top Load Balance Housing & Internal Parts.............................................5-2
5-2 Round Pan Block Style InCal Balance: Housing & Internal Parts .............................5-4
5-3 Square Pan Block Style Square Pan Balance: Housing & Internal Parts..................5-6
5.4 Precision Draft Shield Balance with Draft Shield: Housing & Parts...........................5-8
5.5 Analytical Balance: Housing & Internal Parts..........................................................5-10
5.6 Precision Balance Load Cell & Parts......................................................................5-12
5.7 Analytical Balance Load Cell & Parts.....................................................................5-14
5.8 Block Style InCal Load Cell & Parts .......................................................................5-26
C-1 Com Port Configuration Menu.............................................................................C-1
C-2 The Software Service Tool’s Restore EEProm Tab.............................................C-2
C-3 The Software Service Tool’s Replace Load Cell Tab..........................................C-3
C-4 The Software Service Tool’s Replace PCB Tab..................................................C-4
C-5 The Software Service Tool’s Download Software Tab ........................................C-5
C-6 The Software Service Tool’s Diagnostics Tab.....................................................C-6

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