OHAUS Pioneer User manual

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

TABLE OF CONTENTS
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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TABLE OF CONTENTS
Page No.
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 Linear Calibration......................................................................................... B-3
Pioneer™ Balances Service Manual ii Ohaus Corporation www.ohaus.com

TABLE OF CONTENTS
Page No.
APPENDIX C SOFTWARE SERVICE TOOL INSTRUCTIONS
C.1 Restore EEPROM Data............................................................................................ C-2
C.2 Replace Load Cell ....................................................................................................C-3
C.3 Install new Main Printed Circuit Board......................................................................C-4
C.4 Update Software in the Balance...............................................................................C-5
C.5 Diagnostics...............................................................................................................C-6
C.5.1Incal Weight Mechanism Testing .........................................................................C-6
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
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TABLE OF CONTENTS
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
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
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TABLE OF CONTENTS
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
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
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TABLE OF CONTENTS
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
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
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TABLE OF CONTENTS
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
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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