Service Manual - Test Equipment Depot
Contents
1. then done and then revert to weighing Remove the calibration weight NOTE The calibration procedure can be canceled at any time by pressing the Exit button or turning the scale off 3 9 MENU 3 9 1 Menu Structure The FD Series menu structure consists of three levels Main Sub menu and Menu item The Main menu contains the Sub menus and each Sub menu contains several Menu items Each Menu item contains two or more settings TABLE 3 6 MENU STRUCTURE nu Sub menu BEL UP Menu item rESEE i 1 nd EC LI E bEEP CHAPTER A REPAIR PROCEDURES 4 REPAIR PROCEDURES This section describes how to change individual components of the FD Series Scales When doing this please refer to the exploded view drawings and parts lists in Section 5 Important After replacing components an operational test of the scale must always be carried out see Section 3 6 4 1 REMOVING TOP HOUSING To gain access to the components in the scale perform the following procedures 1 Remove power from the scale by disconnecting the AC adapter Make sure the scale is off 2 Carefully lift and remove the Pan from the scale 3 Unscrew and remove the four Pan Support Caps from the top of the scale 4 Turn the scale over and remove the four screws which hold the Top Housing Refer to Figure 4 1 Top Housing Retaining Screws Location TOP HOUSING RETAINING SCREWS Figure 4 1 Top Housing Retaining Screws Locati2. 10 3 4 SUM 1 SUM 5 Mean SUM 10 Variance SUM 9 6 Mean 2 o Variance o After recording the ten weight readings in the Weight column perform the following steps NOOR WD Record the sum of the ten weight readings here Record the Mean Avg of the ten weight readings here SUM divided by 10 For each weight reading subtract the calculated Mean and record the result For each weight reading record the square of the Weight Mean from step 3 Record the sum of the squared Weight Mean values from step 4 Record the Variance of the ten weight readings here SUM divided by 9 Record the Standard Deviation of the ten weight readings here square root of the Variance 3 9 CHAPTER 3 SCALE TESTING AND CALIBRATION 3 6 2 Repeatability Test Cont Figure 3 6 Sample Calculation of Standard Deviation 6 for FD3 Scale Reading Weight kg Weight Mean Weight Mean 3000 5 0 4 0 16 2 3000 0 0 1 0 01 3 3000 5 0 4 0 16 4 3000 0 0 1 0 01 5 3000 5 0 4 0 16 6 3000 0 0 1 0 01 7 2999 5 0 6 0 36 8 3000 0 0 1 0 01 9 3000 0 0 1 0 01 10 3000 0 0 1 0 01 SUM 30 001 SUM 0 9 Mean SUM 10 Variance SUM 9 0 1 Mean 3 000 1 o v Variance 0 316228 NOTE Theabovetable represents a passing test The results must be less than or equal to the Repeatability shown in table 3 4 3 6 3 O
3. 95105 EE 3 5 E sri PIT 3 6 3 5 1 Precautions tor Battery REES gegeen deier 3 6 20025 sep UT IU TTE 3 6 SR SE ie u elle EE 3 8 3 6 1 Segment Display Test EE 3 8 os Te ele CT EE 3 8 s mE cec Boo EE 3 10 A TT nr 3 11 A EE EE 3 12 38 COMICO WEE 3 13 3 8 1 Calibration POMS METTE TP PP 3 13 A A A E 3 13 3 8 3 Linearity Calibration Pe UEM 3 14 SUME Arm ETT 3 14 SUPER USE RE a 3 14 CHAPTER 4 REPAIR PROCEDURES 4 Jesi c A AA Removing TOP HOUSING entscheede A 4 2 Replacing the Membrane Switch vicio ls 4 2 AS Main PC Board LCD 6010060601 dee EE ENEE EEN 4 3 4 3 1 Main PC Board Replacement viii ponere eru unten betae ness 4 3 43 2 LCD A a an iaa a 4 4 4 4 Replacing the Load Cell Assembly with frame AAA 4 5 4 5 Replacing the Load Cell Component ANNER 4 6 4 5 1 Overload Protection Stop Adjustment s ee 4 6 46 Replacing Me BOTA sarnanes iia 4 7 CHAPTER 5 PARTS LISTS 9 Pans LISIS vs Tre cel alt in loa pl oan 9 1 5 1 FD Series Scales Exploded VIBW osa casi 5 2 APPENDIX A SERVICE MENU insect A Entering RT A 1 ek een E A 1 Elle M cc A 1 Geographical Adjustment Factor ar TT A 2 Sele Reo logs Mr A 2 RAMD MM A 3 TABLE NO 1 1 2 1 2 2 2 3 2 4 2 5 2 6 2 7 3 3 2 3 3 3 4 3 5 3 6 4 4 2 5 A FIGU
4. 5 mm 0 019 in 6 kg 1 0mm 0 039 in 0 4mm 0 015in 0 75mm 0 029 in 15 kg 2 1 mm 0 082 in 0 55 mm 0 021 in 1 0 mm 0 039 in 6 Reassemble the scale 7 Calibrate the scale using Appendix A instructions Check all operations 4 6 REPLACING THE BATTERY This procedure is used when it is required to change the Battery WARNING DEATH OR SERIOUS INJURY CAN OCCUR eCharge the battery only with the charger in the scale Charging the battery under any other conditions may cause the battery to overheat emit hydrogen gas leak ignite or burst e Operate the battery at normal temperature range as specified for the scale e Do NOT short the battery terminals under any conditions eDo NOT dispose of the battery in incinerators or crush or try to open Dispose of the defective battery in accordance with local regulations for lead acid type batteries CAUTION e Check the battery for any sign of irregularities in appearance If there is any damage tothe case such as cracks deformation or leakage replace the battery with a new one e Do NOT charge the battery with the charger terminals reversed 1 Refer to Section 4 1 and remove Top Housing 2 Disconnect the wire Harness from the battery 3 Remove the two screws holding the Battery Holder on top of the Battery These screws are reached from underneath the scale on the Base Housing 4 Lift the Battery out of the Base Housing 5 Position the new Battery in p
5. Place masses totaling 1 3 of the capacity of the scale on the Pan and note the weight Set this mass aside it will become the test mass Place masses totaling 1 3 of the capacity of the balance on the Pan and zero the scale Place the test mass on the Pan and record the weight Place masses totaling 2 3 of the capacity of the scale on the Pan and zero the scale Place the test mass on the Pan and record the weight The difference of the 3 recorded weights should be less than or equal to the tolerance values listed in Table 3 4 CHAPTER 3 SCALE TESTING AND CALIBRATION 3 7 SPECIFICATIONS TABLE 3 4 SPECIFICATIONS Model Capacity x Readability Max x d non approved FD3 FD6 FD15 3 kg x 0 0005 kg 6 kg x 0 001 kg 15 kg x 0 002 kg 3000gx0 5g 6000gx1g 15000 9x2 Y 6 Ib x 0 001 Ib 15 Ib x 0 002 Ib 30 Ib x 0 005 Ib 96 oz x 0 02 oz 240 oz x 0 05 oz 480 oz x 0 1 oz 480 oz x 1 4 oz 30 Ib O oz x 0 1 oz 30 Ib O oz x 1 4 oz 240 oz x 1 4 oz 15 Ib O oz x 0 1 oz 15 Ib O oz x 1 40z 96 oz x 1 4 oz 6 Ib O oz x 0 1 oz 6 IbO oz x 1 4 oz Maximum displayed resolution 1 6000 1 7500 1 7500 Capacity x Readability 3 kg x 0 001 kg 6 kg x 0 002 kg 15 kg x 0 005 kg Max x e approved 3000gx1g 6000 gx2g 15000 gx5qg 6 Ib x 0 002 Ib 15 Ib x 0 005 Ib 30 Ib x 0 01 Ib 96 oz x 0 05 oz 240 oz x 0 1 oz 480 oz x 0 2 oz 96 oz x 1 4 oz 240 oz x 1 4 oz 480 oz x 1 4 oz Approved resolution 1 3000 1 3000 1 3000 Repeatabilit
6. Section 4 1 and leave the Membrane Switch connected to the scale Disconnect the battery Disconnect the Load Cell cable from connector J1 on the main PC Board Refer to Figure 3 2 for location With the Simulator set to zero connect the Simulator to connector J1 using Alligator clips Connect a known good AC Adapter to the scale and connect to a power source Turn on the scale CLEAR PAN ERROR 14 should be displayed This is normal Set the scale to indicate weight in kilograms kg and set the calibration value to maximum span value Review Table 3 2 and adjust the Simulator to simulate 0 load 50 load and 100 load for the capacity that the scale is rated for If the resulting readings are unstable the Main PC Board is defective Use the Simulator to calibrate the scale in the next procedure to verify ifthe Main PC Board is good or bad Calibration Test This test calibrates the scale using the simulator and can verify that the Main PC Board is functioning properly or improperly l 2 With the scale on and the Membrane Switch connected enter the scale menu and perform a span calibration according to the Instruction Manual Follow the scale prompts When the scale indicates a given weight should be placed on the scale set the simulator to an equivalent value based on Table 3 2 For example when a span value of 6 kg for a 6 kg scale is shown the simulator should be set to 8 mV V 3 5 CHAPTER 3 SCALE TESTING AND CA
7. Series Scales 5 2 CHAPTER 5 PARTS LISTS TABLE 5 1 FD SERIES SCALES PARTS LIST 5 3 ITEM NO PART NO DESCRIPTION QUANTITY 71172937 Seal Adapter amp Foot Switch Socket FD 2 80500435 AC Adapter US 120 Volts 60 Hz 2 80500521 AC Adapter US 220 Volts 60 Hz 2 80500437 AC Adapter UK 230 Volts 50 Hz 2 80500436 AC Adapter EU 230 Volts 50 Hz 2 80500462 AC Adapter AU 240 Volts 50 Hz 2 71143794 AC Adapter JP 110 Volts 50 Hz 1 3 71167489 Base Housing FD 1 4 71168359 Rechargeable Battery Pack FD 1 5 71172938 Battery Holder FD 1 6 71172932 Top Housing 1 7 71167490 Pan FD 1 8 71158353 Harness Rechargeable Battery FD 1 9 71119058 Load Cell 3 kg FD 1 9 71123142 Load Cell 6 kg FD 1 9 71123141 Load Cell 15 kg FD 1 10 71172916 Load Cell with Spiders 3 kg FD 10 71172917 Load Cell with Spiders 6 kg FD 1 10 71172918 Load Cell with Spiders 15 kg FD 1 71172934 Harness Adapter amp Foot Switch FD 12 71172940 Pan Support Caps 4 FD 13 71172933 LFT Sealing Kit 1 14 71169710 Membrane Switch FD 1 15 71158347 LCD Display FD 1 16 71158350 Main PCB with LCD FD 1 17 71172935 Level Bubble FD 1 18 71167481 Gasket FD 1 19 71172939 Adjustable Feet 4 FD 1 Not Shown 71172941 Hardware Kit CHAPTER 5 PARTS LISTS 5 4 APPENDIX A SERVICE MENU A INTRODUCTION This section describes the Service menu and sub menus which allow authorized service personnel to perform factory settings and c
8. steps 1 through 4 of Section 4 3 1 2 Carefully unsolder all contacts of the LCD and remove the LCD 3 Replace the LCD and solder all connections check the Main PC Board and make sure that solder has not spilled over to other connections 4 Continue with steps 5 through 16 of Section 4 3 1 CHAPTER A REPAIR PROCEDURES 4 4 REPLACING THE LOAD CELL ASSEMBLY WITH FRAME The Load Cell Assembly is centrally located inside the scale The Load Cell is factory assembled and the overload protection stops are pre adjusted There are no adjustments to be made on this assembly after installation 1 Refer to Section 4 1 and remove Top Housing 2 Remove connector from J1 on the Main PC Board 3 Remove the four screws holding the Load Cell Assembly to the bottom housing See Figure 4 3 for screw locations LOAD CELL e RETAINING SCREWS Ps LOAD CELL Y RETAINING SCREWS Figure 4 3 Load Cell Retaining Screws 4 Lift the Load Cell Assembly out of the bottom housing and replace with a new one Install screws 5 Connect connector J1 to the Main PC Board 6 Position the upper housing in place over the scale and connect the flexible cable from the membrane switch to connector J2 on the Main PC board 7 Check the LFT lock switch Make sure it is in the OFF position 8 Turn on the scale When self testing is completed the display may indicate an error code This is normal 9 Calibrate the scale according to the instructi
9. 0 Hz UK Ohaus P N 80500437 AC Adapter 240 V 50 Hz AU Ohaus P N 80500462 AC Adapter 100 V 50 Hz JP Ohaus P N 71143794 NOOR WN NOTE Adapters required for servicing are location dependent 13 CALIBRATION MASSES REQUIRED The masses required to test the FD Series Scales must meet the requirements of ASTM Class 4 or OIML Class F2 The mass values are listed in Table 1 1 Bolded values are default settings TABLE 1 1 CALIBRATION MASSES Mop Span Cal Choices Linearity Cal fixed Service Calibration Cal in kg Masses Totaling Masses Totaling Masses Totaling FD3 1 kg 2 kg 3 kg 1 or 2 kg amp 3 kg 1 kg amp 3 kg FD6 2 kg 4 kg 6 kg 2 or 4 kg amp 6 kg 2 kg amp 6 kg FD15 5 kg 10 kg 15 kg 10 kg amp 15 kg 5 kg amp 15 kg 14 SERVICE STRATEGY The repair method for the FD Series Scales is the direct substitution of major assemblies The available repair parts are listed in Table 5 1 The FD Series Scales contains 4 major replaceable assemblies Cover Assembly with Membrane Switch Load Cell Assembly with Frame Lead Acid Rechargeable Battery and the Main PC Board with LCD NOTE The Load Cell LCD and Membrane Switch may also be ordered and replaced separately This service manual contains sufficient information to isolate the problem replace the component test and restore the Scale to original factory specifications CHAPTER 2 DIAGNOSIS 2 DIAGNOSIS This section contains information needed to properly eva
10. 600 2925 North or South in Elevation above sea level in feet degrees and minutes 0 00 5 46 5 46 9 52 9 52 12 44 12 44 15 06 15 06 17 10 17 10 19 02 19 02 20 45 20 45 22 22 22 22 23 54 23 54 25 21 25 21 26 45 26 45 28 06 28 06 29 25 29 25 30 41 30 41 31 56 31 56 33 09 33 09 34 21 34 21 3531 35 31 36 41 36 41 37 50 37 50 38 58 38 58 40 05 40 05 41 12 41 12 42 19 42 19 43 26 43 26 44 32 44 32 45 38 45 38 46 45 46 45 47 51 47 51 48 58 48 58 50 06 50 06 51 13 51 13 62 22 62 22 53 31 53 31 54 41 54 41 56 52 56 52 57 04 57 04 58 17 58 17 9 32 59 32 60 49 60 49 62 09 62 90 63 30 63 30 64 55 64 55 66 24 66 24 67 57 67 57 69 35 69 35 71 21 71 21 73 16 73 16 75 24 75 24 77 52 77 52 80 56 80 56 85 45 85 45 90 00 306 04000 JJ Oo om o P P D D H o cO O OO JJ Oo OO o P P CO CO ID h aa 00 NN NO OO OO Om SS GO GO h za za OO OH Test Equipment Depot 800 517 8431 99 Washington Street Melrose MA 02176 TestEquipmentDepot com 802 5 09 0 6 PN 80250906 SERVICE MANUAL FD SERIES S
11. CALES
12. INAL OUTPUT IN MILLIVOLTS AT 5 VOLTS EXCITATION CAPACITY NO LOAD 5096 10096 3 kg 1 2 41 5 no load 2 2 no load 4 4 6 kg 0 4 1 5 no load 2 0 no load 4 0 15 kg 0 2 1 5 noload 2 5 no load 5 0 BATTERY AC ADAPTER CONNECTOR O EXTERNAL TARE SWITCH TESTPOINTS e e e e TOP VIEW PCB EXE BLK SIG RED Ji LOAD CELL LCD DISPLAY JUMPER LEAVE INSTALLED MEMBRANE SWITCH Figure 3 2 FD Series Scales Interconnection Diagram 3 3 CHAPTER 3 SCALE TESTING AND CALIBRATION 3 4 TESTING THE MAIN PC BOARD The Main PC Board can be tested by measuring voltages and by using a simulator The simulator replaces the Load Cell during testing and is a useful tool for diagnosing problems 3 4 1 Main PC Board Voltage Measurements Prior to making the voltage measurements the battery should have been fully charged and tested 1 Disconnect power from the scale 2 Remove the Top housing refer to Section 4 1 and leave the Membrane Switch connected to the scale 3 Disconnect the battery from the Main PC Board 4 Connect the AC Adapter to the scale b Refer to Figure 3 2 Interconnection Diagram which illustrates the interconnections to the Main PC Board and is shown as a top view 6 Turn the scale on 7 Using a DVM measure fhe excitation voltage across pins 1 and 4 of JI that should be 5 volts dc This is the excitation voltage for the Load Cell and is regulated Ifthe voltag
13. LIBRATION Calibration Test Cont 3 Upon completion of calibration the Main PC Board can be further checked using the Simulator to simulate various weight values If simulator settings and weight reading on the scale agree the Main PC Board is functional If the scale readings vary or do not agree with readings in Table 3 2 the Main PC Board is defective and should be replaced 4 Remove power from the scale and proceed with Section 4 3 and replace the Main PC Board b After Main PC Board replacement and assembly of the scale perform Operational Tests in Section 3 6 3 5 TESTING THE BATTERY The FD Series Scales contains a rechargable 6 0 Volt 4 5 Ampere rated Lead Acid Battery 3 5 1 Precautions for Battery Handling WARNING DEATH OR SERIOUS INJURY CAN OCCUR e Charge the battery only with the charger inthe scale Charging the battery under any other conditions may cause the battery to overheat emit hydrogen gas Leak ignite or burst e Operate the battery at normal temperature range as specified for the scale e Do NOT short the battery terminals under any conditions e DoNOTdispose ofthe battery in incinerators or crush or try to open Dispose of the defective battery in accordance with local regulations for lead acid type batteries CAUTION e Check the battery for any sign of irregularities in appearance If there is any damage to the case such as cracks deformation or leakage replace the battery with a new one e Do
14. NOT charge the battery with the charger terminals reversed 3 5 2 Botten Tests A new battery when installed in the FD Series Scales will provide many years of useful service The length of service depends upon the type of use of the scale If left connected to the AC Adapter all of the time the battery receives a small charge when the battery voltage is low service life can be many years The FD Series Scales can be operated for up to 120 hours per charge Battery life can be maximized by frequent charging 1 Upon receipt of the scale plug in the AC Adapter to a power source and the scale Allow the battery to charge Ifthe battery required a charge the battery indicator on the front of the LCD display will indicate charging 2 Refer to Section 4 1 and remove the Top Housing Leave the Membrane Switch on the cover connected to the scale 3 6 CHAPTER 3 SCALE TESTING AND CALIBRATION 3 5 2 Battery Tests cont 3 With the AC Adapter connected measure the battery voltage at the battery terminals the voltage should be approximately 6 to 7 Volts de when charging The voltage should be approximately 6 4 Volts dc ten minutes after charging stops The scale will operate until the battery voltage drops to approximately 5 6 Volts dc NOTE If the scale operates less than 120 hours charge the battery and turn on the scale and test how long the scale operates If the scale operates less than 60 hours with no backlight the battery should be r
15. RE NO 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 4 1 4 2 4 3 5 1 A 1 TABLE OF CONTENTS Cont LIST OF TABLES TITLE PAGE Calibration MASSES TREE EET EET 1 2 Scale Will Not Turn On With AC Adapter A 2 1 Scale Will Not Turn On Using Battery Power ANNER 2 2 Scale Does Not Respond To Front Panel Control 2 3 No Display or Partial RT e VE 2 3 Balance Readings Incorrect or Unstable raciocinio goe Sege Seege 2 4 banmor Cala MO SDU G caue dadas ibas eege 2 4 FD Series Scales Error E 2 5 Load Cell Resistance Readings reene 3 2 Load Cell Output Readings EE 3 3 o 3 7 A 3 12 Calibration POMS tT 3 13 EE TEE 3 14 Load Cell Screw Torque Information cccccccccnnncocoonoooonnnnnnonorooos 4 6 Load Cell Overload Protection Stop Gap settings 4 7 FD Series Scales Parts List RTT TO o T T 5 3 Geographical Adjustment Values eem A 4 LIST OF ILLUSTRATIONS TITLE PAGE FD Series Scales Membrane Switch Wiring Diagram sssssee 3 1 FD Series Scales Interconnection Diagram AAA 3 3 Segment IIS le 3 8 Standard Deviation Worksheet eene 3 9 Calculation of Standard WAT a EEN 3 9 Sample Calculation of Standard Deviation oooccccccccccccccnnnonncno 3 10 Off Center Load Test Weight Locations AAA 3 10 Security Switch SHOWN in On Position sciiicet te nre perte to Rea n 3 15 APP CO green 3 15 Top Housing
16. Retaining Screw Locations oen irren t tenen 4 Connector EOOHI I8 ada 4 3 Load Cell Retaining Screws E 4 5 Exploded View of FD Series SEUS aiii 5 2 581 109 OUR aa po E A 1 CHAPTER 1 INTRODUCTION 1 INTRODUCTION This service manual contains instructions for the diagnosis and repair work to be performed by Ohaus Dealers or Ohaus authorized service centers Knowledge of the operation of the Scale is assumed Instruction manuals may be required with this service manual For complete information on operation refer to the Instruction Manual This manual covers maintenance on the following FD Series Scales Models FD3 FD6 and FD15 The contents of this manual are contained in five chapters and an Appendix with service menu instructions Chapter 1 Introduction Contains information about service facilities tools test equipment test masses and service strategy Chapter 2 Diagnosis Contains information on problem verification scale examination preliminary checks and troubleshooting tables Chapter 3 Testing Contains testing procedures interconnection diagrams and wiring diagrams performance tests specifications and calibration Chapter 4 Repair Procedures Contains detailed repair procedures for all major components Chapter 5 Parts Lists Contains an exploded view identifying all serviceable replacement components with associated parts lists Appendix A Service Menu Contains Capacity Geographical Code Servic
17. TES 1 The following steps involve power applied to the scale 2 Solder contacts located above connector J1 can be used as measuring points See Figure 3 2 1 Insert the 4 Pan Support Caps into the Load Cell Frame and place the Pan on top 2 Turn on power to the scale by momentarily connecting pin 1 and 5 on J2 3 With noloadonthe Pan first measure the excitation voltage across pins 1 and 4 of J1 onthe PCB This voltage must be 5 0 Volts dc with the Load cell connected If the voltage is lower disconnect the Load Cell cable from the PC Board and measure again If the voltage is 5 Volts dc the Load Cell is defective and must be replaced If the voltage remains low the regulated 5 volt power supply on the PC Board is defective and the Main PC Board must be replaced For Main PC Board replacement see Section 4 3 3 2 CHAPTER 3 SCALE TESTING AND CALIBRATION 3 3 3 Excitation and Output Voltage Test Cont 4 Measure the voltages on J1 across pins 2 and 3 SIG and SIG points These measurements represent the direct output of the Load Cell Repeat measurements at 5096 and full scale capacities See Table 3 2 for typical readings NOTE Table 3 2 indicates typical readings actual values can vary as much as 1 5 mV but should remain linear throughout the entire range If readings are out of tolerance replace the Load cell See Section 4 4 for Load Cell replacement TABLE 3 2 LOAD CELL OUTPUT READINGS NOM
18. Test Equipment 99 Washington Street Depot Melrose MA 02176 Phone 781 665 1400 OHAUS 1 800 517 8431 Toll Free 1 800 517 8431 FD SERIES SCALES SERVICE MANUAL O OHAUS FD SERIES SCALES SERVICE MANUAL The information contained in this manual is believed to be accurate atthe 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 2004 Ohaus Corporation all rights reserved Registered trademark of Ohaus Corporation TABLE OF CONTENTS CHAPTER 1 INTRODUCTION Page l lu s d rs o NEEN 1 1 MEE 005 66 EE 1 1 Ez Tools and EMM Maa ee eR ent E er 1 2 1 24 Standard Tools and Test Eguipielil eege e e 1 2 122 2 PO MOONS E 1 2 l Calibration Masses Hat 1 2 EE e VE 1 3 CHAPTER 2 DIAGNOSIS d Boon c rp 2 1 ZA elle Eelere EXA A id 2 zur Jer CNBR A O o adis Eege 2 Troubleshooting TADOS v derse dia 2 2 4 FD Series Scales Error Code TADO mesones doi Ras EB ia pias icubadds 2 5 CHAPTER 3 SCALE TESTING AND CALIBRATION 3 EE 3 1 Sheet Eeer 3 1 3 2 1951106109 Membrane SWITCH aca 3 1 3 3 195110 TNE Load Cell ASSSITIDIV EE 3 2 Geck Kam tee ee ed Ee 3 2 mo 2691500069 EE 3 2 3 3 3 Excitation and Output Voltage Test escocia eii 3 2 24 9651101119 Mdin PG BOG EE 3 4 3 4 1 Main PC Board Voltage Measurements AANEREN 3 4 34 2 5110061610
19. ain PC Board if defective should be replaced See Repair Procedures 4 3 After repair perform Operational Tests in Section 3 6 2 4 2 4 FD SERIES SCALES ERROR CODE TABLE The FD Series Scales is equipped with software which will display an error condition when it occurs Review the listed codes and follow instructions to correct the problem CHAPTER 2 DIAGNOSIS TABLE 2 7 FD SERIES SCALES ERROR CODES ERROR CODE CAUSE REMEDY Error 1 The load onthe Pan exceeds Remove excess load Turn scale off then the rated capacity ofthescale on Overload condition H the scale was turned on Remove excess load cycle power offthen with a load on the pan on Needs calibration Perform service calibration see Appendix A Damaged Load Cell Test the Load Cell see Section 3 3 If defective replace see Repair Procedures 4 4 Mfter repair perform Operational Tests see Section 3 6 Error 2 Pan missing Replace the Pan Underload condition Needs calibration Press the ON ZERO Off button if No appears turn power to the scale off then on If the problem persists perform cali bration in Section 3 9 Damaged load cell If the problem still persists refer to Table 2 5 and follow the remedies under Load Cell Damaged Error 9 Checksum error See Appendix A Service Menu check ca Configuration data pacity Needs calibration Perform service calibration see AppendixA PCB defective If error persis
20. alibration as well as setting the Geo code There is also a ramp display used to indicate the condition of the load cell Please refer to the Service Menu diagram Y gt CAP GEO gt CAL RAMP gt E PAND gt END no no no no no no A A A A lyes Im ves yes vs je Y Y Adjust Adjust Perform Display Factory Exits to Capacity Geo Calibration Ramp use only weighing Factor Y Value yes yes Ex yeso no yes Weigh Mode Figure A 1 Service Menu Diagram A 1 ENTERING SERVICE MENU 1 The following conditions must be met before entering the Service menu e The security switch must be in the OFF position e LEI must be turned OFF in the Setup menu See note e The calibration Lock must be set to OFF in the Lock menu See note NOTE This requirement is waived when EEPROM checksum is erroneous 2 Turn the scale on 3 The Service menu is entered by pressing and holding the TARE and G N T buttons together for at least 10 seconds until SERVE is displayed briefly followed by CAP A 2 NAVIGATION In general a blinking item on the display indicates a choice is available Pressing Yes button accepts the displayed choice pressing No button advances to the next choice or to the next menu Pressing Exit button exits the service menu and returns 10 displaying the weight Pressing Back butt
21. be made to ascertain whether or not the scale meets specifications 3 1 TESTING THE AC ADAPTER The AC Adapters are available with different input voltages Before testing the Adapter make sure the Adapter rating agrees with the power source being used All Adapters are rated with an output of 9 V dc at 500mA Adapters can fail by having shorted internal windings producing low voltage output or no output at all 1 Plug the AC Adapter in a suitable power source and measure the open circuit voltage on connector it should be 10 V dc to 17 V de Perform procedure Section 4 1 and remove Top Housing Plug the AC Adapter into the scale and measure the test points for the AC connector see Figure 3 2 The output voltage should be 9 Volts dc minimum and 14 Volts dc maximum If the voltage is below or above these readings replace the Adapter 3 2 TESTING THE MEMBRANE SWITCH The Membrane switch can be tested after removing the Top Housing from the Base Housing l 2 MEMBRANE 3 SWITCH Refer to Section 4 1 and remove the Top Housing Refer to Figure 3 1 Using an Ohmmeter measure the resistance between pin 5 to all other pins onthe membrane switch cable the readings should be infinite resistance Then press each button and check that the resistance is zero for each button If continuity is not present the membrane Switch is defective Replace the Membrane Switch Check that the Membrane Switch is not shorted to the Top Housin
22. cations Remove connector from J1 which is used to connect the Load Cell Remove the four corner screws on the Main PC Board Replace the Main PC Board and install the four screws previously removed Replace connector J1 Replace the BAT and PWR connectors on the Main PC Board Position the Top Housing in place over the scale and connect the flexible cable from the membrane switch to connector J2 on the Main PC Board Check the LFT lock switch legal for trade switch Make sure it is in the OFF position 10 Turn on the scale When self testing is completed the display may indicate an error code This is normal 4 3 CHAPTER 4 REPAIR PROCEDURES 4 3 1 Main PC Board Replacement Cont 11 Set the capacity see Appendix A 3 12 Calibrate the scale according to the Instructions in Appendix A 13 Turn the scale off then on It will go through all the self testing 14 Reassemble the scale 15 Replace the Pan Support Caps and Pan on top of the scale 16 After repair perform operational test see Section 3 6 If possible set the original customer settings back into the scale 4 3 2 LCD Replacement This procedure is done when the LCD shows signs of visible damage such as cracked glass or partial displays and the scale operates normally in all other functions The Main PC Board has to be removed for this procedure NOTE This procedure is very difficult and should not be attempted unless you have the proper tools 1 Perform
23. dropping the scale The ramp function displays the duty cycle of the A D converter output to within one tenth of a percent When in the ramp menu placing a small weight on the Pan will cause the reading to increment slightly Placing additional weights of the same value will also increment to a greater displayed value This is normal operation A Load Cell that is damaged will be non linear as additional weights are added and might also have rapidly changing numbers In this case the Load Cell must be replaced l 2 When RAMP is displayed press the Yes button to display the scales ramp values With an empty Pan record the no load ramp value Place half load on the pan and record the ramp value Place a full load on the Pan and record the ramp value Subtract the no load ramp value from the half load ramp value Subtract the half load ramp value from the full load ramp value The two calculated values should be equal The ramp value should be between 20 to 60 throughout testing Values outside of this range indicate the load cell should be replaced At the end of the testing press the Yes button E PAND is displayed disregard this display as it is not used Press the No button END is displayed Press the Yes button to exit and return to the weighing mode A 3 APPENDIX A SERVICE MENU TABLE A 1 GEOGRAPHICAL ADJUSTMENT VALUES Elevation above sea level in meters away from the equator 325 650 975 1300 1625 1950 2275 2
24. e Calibration and Ramp information for the FD Series Scales in a service mode 1 1 SERVICE FACILITIES The service area should be a stable environment The bench area should be clean and should contain an antistatic mat with a personnel grounding clip 10 protect internal circuit boards The ideal electrical power source for the scales should be a dedicated line to avoid sudden fluctuations or voltage drops caused by external equipment drawing heavy current The service area for the scales should be away from direct sunlight overhead heating or air conditioning ducts magnetic fields such as motors large transformers or vibrating sources such as machinery The power outlet should be grounded for safety Sufficient space should be provided around the scale as not to be affected by other equipment This will ensure that the scale is operated under ideal conditions CHAPTER 1 INTRODUCTION 1 2 TOOLS AND EQUIPMENT 1 2 1 Standard Tools and Test Equipment The service shop should contain the following equipment 1 Digital Voltmeter DVM 2 Standard Electronics tool kit 3 Desk magnifier on a stand 4 Grounding mat and clip 5 Razor blades 1 2 2 Special Tools To service the Ohaus FD Series Scales the following equipment is recommended 1 A Load Cell Simulator AC Adapter 120 V 60 Hz US Ohaus P N 80500435 AC Adapter 220 V 60 Hz US Ohaus P N 80500521 AC Adapter 230 V 50 Hz EU Ohaus P N 80500436 AC Adapter 230 V 5
25. e is lower replace the Main PC Board refer to Section 4 3 and then perform Operational Tests in accordance with Section 3 6 8 Measure incoming power from the AC Adapter connector shown in Figure 3 2 The voltage should read between 9 and 14 volts dc with power off and above 9 Volts dc with power on 9 With the battery disconnected from the main PC Board measure voltage across pins 1 and 3 on the battery connector on the PC Board The voltage should read 1 to 3 Volts dc 10 Connect the battery to the Main PC Board and measure the voltage across pins 1 and 3 on the battery connector The full battery voltage should read a minimum of 6 0 Volts dc If the voltage is lower the battery may require charging or it may be defective Refer to section 3 5 and test the battery 11 Perform simulator testing 3 4 CHAPTER 3 SCALE TESTING AND CALIBRATION 3 4 2 Simulator Testing To perform these tests the use of a Simulator is required The basic function of a Simulator is to simulate the output of a full bridge Load Cell allowing the scale to be separated from the Load Cell for the purposes of troubleshooting and calibration The Load Cell used in the scale is rated at 2mV V output with a 5 Volt excitation voltage applied General Load Test This test checks the Main PC Board circuitry by simulating accurate load cell voltages at 096 50 and 100 load capacities 1 2 Disconnect power from the scale Remove the Top housing refer to
26. em brane Switch Replace if necessary See Repair Procedure 4 2 If the scale fails to tum on with a new Membrane Switch the Main PC Board should be tested in accordance with Section 3 4 The Main PC Board if defec tive should be replaced See Repair Procedures 4 3 After repair perform Operational Tests in Section 3 6 2 2 CHAPTER 2 DIAGNOSIS TABLE 2 3 SCALE DOES NOT RESPOND TO FRONT PANEL CONTROLS SYMPTOM PROBABLE CAUSE REMEDY Scale does not respond to front panel controls Membrane Switch is defec tive Refer to Section 3 2 and test the Mem brane switch Replace if necessary See Repair Procedure 4 2 If membrane switches are OK refer to Section 3 4 and test the Main PC Board If defec tive replace the Main PC Board See Repair Procedures 4 3 After repair perform Operational Tests in Section 3 6 TABLE 2 4 NO DISPLAY OR PARTIAL DISPLAY SYMPTOM PROBABLE CAUSE REMEDY Display is noton or partial char acters are displayed Main PC Board is defective or LCD may be defective NOTE Ifthe LCD shows signs of damage such as cracked dim or partial characters the LCD should be replaced The Main PC Board is replaced as a whole assembly Check procedures in Tables 2 1 2 2 and 2 3 first and verify that other problems do not exist Then refer to Section 3 4 and test the Main PC Board Replace Main PC Board or LCD See Repair Procedures 4 3 After r
27. epair perform Operational Tests in Section 3 6 2 3 CHAPTER 2 DIAGNOSIS TABLE 2 5 BALANCE READING INCORRECT OR UNSTABLE SYMPTOM PROBABLE CAUSE REMEDY Balance reads incorrectly Balance reading unstable Needs calibration Load Cell is damaged Main PC Board defective Perform Service Calibration in Appen dix A If calibration fails refer to Table 2 6 Test the Load Cell refer to Section 3 3 If defective replace see Section 4 4 After repair perform Operational Tests in Section 3 6 The Main PC Board should be tested in accordance with Section 3 4 The Main PC Board if defective should be re placed See Repair Procedures 4 3 After repair perform Operational Tests in Section 3 6 TABLE 2 6 CANNOT CALIBRATE THE SCALE SYMPTOM PROBABLE CAUSE REMEDY Scale can be turned on but will not calibrate Incorrect weights LFT lock switch is in the locked position and or The software lock menu is setto ON Review software menu items Load cell assembly defec tive Main PC Board defective Verify that proper weights are used Set LFT lock switch to unlocked position see Figure 3 2 and or Set the software lock menu to OFF Test the Load Cell refer to Section 3 3 If defective replace see Section 4 4 After repair perform Operational Tests in Sec tion 3 6 The Main PC Board should be tested in accordance with Section 3 4 The M
28. eplaced This is 5096 capacity 4 Table 3 3 indicates the capacity of the battery in percentage after a full charge Allow a charged battery to stand overnight without being charged and measure the terminal voltage to see capacity of the battery TABLE 3 3 BATTERY CAPACITY Open Circuit Voltage 6 V Battery 0 20 40 60 80 100 Residual Capacity 96 5 If the battery requires replacement refer to Section 4 6 charge the new battery overnight and check scale performance 3 7 CHAPTER 3 SCALE TESTING AND CALIBRATION 3 6 PERFORMANCE TESTS 3 6 1 Segment Display Test Connect the AC Adapter into a suitable power source and connect it 10 the scale Turn the scale on all segments are enabled and displayed briefly followed by a software revision number This is a segment display test Figure 3 3 is a full display test om CI Z ZEE SR AN Y oro w v Figure 3 3 Segment Display Accurate performance of the FD Series Scales is determined by a series of three performance tests Repeatability Test Off Center Load Test and Linearity Test These tests are used to evaluate the scale performance before and after repairs Each scale tested must meet the requirements specified in each test as well as the specifications listed in Tables 3 2 and 3 3 A scale passing each of these three tests complies with Ohaus specifications 3 6 2 Repeatability Test Repeatability is the standard deviation of a set of similar weight
29. ff Center Load Test The Off Center Load Test is used to determine whether displayed weight values will be affected by moving the load to different areas of the weighing Pan See Figure 3 7 Figure 3 7 Off Center Load Test Weight Locations 3 10 CHAPTER 3 SCALE TESTING AND CALIBRATION 3 6 3 Off Center Load Test Cont l 2 Zero the scale Place a test weight equal to 1 2 the scale capacity in the center of the weighing Pan and record the reading Move the test weight to the mid point between the center and the left edge of the weighing Pan and record the reading Move the test weight to the mid point between the center and the rear of the weighing Pan and record the reading Move the test weight to the mid point between the center and the right edge of the weighing Pan and record the reading Move the test weight to the mid point between the center and the front of the weighing Pan and record the reading Subtract the center position reading from the reading at each outer position The difference at each test position should be within the off center load tolerance specified in Table 3 4 3 6 4 Linearity Test The Linearity test is used to determine the linearity of the scale throughout its operating range NOTE The scale must pass the Repeatability and Off Center Load Tests before the Linearity test is performed Before performing this test calibrate the scale according to Appendix A Lm
30. g case Check pins 1 through 5 to the case which should be infinite resistance Reassemble Top Housing to Base Housing COMMON 3 CHAPTER 3 SCALE TESTING AND CALIBRATION 3 3 TESTING THE LOAD CELL ASSEMBLY This section contains three methods of testing the Load cell 3 3 1 Ramp Test Refer to Appendix A and perform the Ramp Test If the Ramp Test passes continue with the rest of this procedure 3 3 2 Resistance Test 1 Refer to Section 4 1 and remove the Top Housing 2 Remove the Load Cell cable connector from J1 on the Main PC Board Using an Ohmmeter measure in accordance with Table 3 1 Load Cell Resistance Readings on the cable If the resistance readings vary more than the table readings allow replace the Load Cell in accordance with the procedure in Section 4 4 This resistance test is useful in determining if the Load Cell has been severely damaged by a short or open circuit which has occurred on the cell or wiring If the Load Cell resistance readings are good continue with this procedure TABLE 3 1 LOAD CELL RESISTANCE READINGS MEASUREMENT POINTS READING Pins 1 amp 4 408 4 10 Ohms Pins 2 amp 3 350 4 4 Ohms NOTE Pins 1 2 3 and 4 must be isolated from chassis ground and shield Resistance should be greater than 5 megohms A lower reading indicates a short in either in the Load Cell cable or the Load Cell 3 Reconnect Load cell cable to J1 3 3 3 Excitation and Output Voltage Test NO
31. l off the protective film from the new Membrane Switch and carefully align and affix to the upper housing 6 Press the Membrane Switch down uniformly Using your fingers with a cloth roll from the center of the Membrane Switch outward towards the edges to remove any air bubbles that may be trapped CAUTION DO NOT PRESS ON THE CLEAR WINDOW AREA OR ON THE SWITCHES 7 Position the Top Housing in place over the base Housing and connect the flexible cable from the Membrane Switch to connector J2 on the Main PC board 8 Reassemble the scale by replacing the four screws at the bottom of the scale which secure the upper housing 9 Replace the Pan Support Caps and Pan on top of the scale 4 2 4 3 CHAPTER 4 REPAIR PROCEDURES MAIN PC BOARD LCD REPLACEMENT The Main PC Board is located inside the scale towards the front To replace the Main PC Board it is necessary to disassemble the scale The LCD may also be replaced as a separate item if cracked or partial displays are shown 4 3 1 l 2 9 Main PC Board Replacement Refer to Section 4 1 and remove Top Housing Remove the BAT connector plug from the Main PC Board which is battery and the PWR connector which is used for external power that connects to the AC Adapter plug on the Base Housing See Figure 4 2 TO AC ADAPTER TO BATTERY CONNECTOR BAT O FUSE 1 1A 30V J O JA JUMPER LFTSWITCH J2 TO MEMBRANE SWITCH Figure 4 2 Connector Lo
32. lace in the Base Housing 6 Reinstall the Battery holder using the two screws 4 7 CHAPTER 4 REPAIR PROCEDURES 4 6 REPLACING THE BATTERY Cont 6 Place the Battery Holder in place over the Battery and secure with the two screws previously removed 7 Attach the two battery wires with clips to the Battery Make sure the Red wire is attached to the positive terminal on the Battery and the Black wire is attached to the negative terminal on the Battery CAUTION Dispose of the Battery according to local regulations for hazardous materials Do not incinerate crush or throw out in regular garbage containers Battery contains an acid solution 4 8 CHAPTER 5 PARTS LISTS 5 PARTS LISTS This section of the manual contains exploded views and parts lists for the FD Series Scales The exploded view drawings identifies the replaceable parts NOTE In all cases where a partis replaced the scale must be thoroughly checked after the replacement is made The scale MUST meet the parameters of all applicable specifications in this manual H further technical information is needed in the United States call toll free 1 800 526 0659 between 8 00 a m and 4 00 p m EST An Ohaus factory service technician will be available to provide assistance Outside the U S A please visit our site www Ohaus com to locate the nearest Ohaus Office 5 1 CHAPTER 5 PARTS LISTS 5 1 FD Series Scales Exploded View Figure 5 1 Exploded View of FD
33. luate the reported problem and diagnose its cause 2 1 SCALE SETUP AND EXAMINATION Set up the scale according to the Instruction manual Allow the scale to stabilize to room temperature Examine the scale for signs of corrosion or physical damage 2 2 PRELIMINARY CHECKS Power up the scale using the customer s ac adapter In the case where the scale will not power up check the ac adapter Observe and record the error codes and software revision Record all menu settings as received 2 3 TROUBLESHOOTING TABLES Troubleshooting tables 2 1 through 2 7 identify actual types of problems that could be encountered with the scale The troubleshooting tables refer to interconnection and wiring diagrams in this section to assist in locating the problem 2 1 SCALE WILL NOT TURN ON WITH AC ADAPTER SYMPTOM PROBABLE CAUSE REMEDY Scale will not turn on with AC Adapter defective Refer to Section 3 1 and check the ac adapter supplied adapter voltage output If voltage is low or nonexistent replace the ac adapter If OK proceed DC input connector at the Referto Section 4 1 and open the scale bottom of scale is defective Reconnect the ac adapter to the scale Check dc voltage on the Main PC Board or test points as shown in Figure 3 2 Voltage should read between 9 and 14 Volts power off and above 9 Volts dc power on If voltage is not present check and replace the Harness If OK proceed Membrane Switch defective Refer
34. on CAUTION Use care in the next step as the membrane switch wiring is attached to the Main PC board 5 Place the scale in the upright position and carefully lift the Top Housing from the Base Housing about 50 8 mm 2 inches to 76 2 mm 3 inches and tilt forward Reach under the Top Housing from the front and carefully disconnect the flexible cable from connector J2 on the Main PC board 6 Set the Top Housing aside 4 1 CHAPTER 4 REPAIR PROCEDURES 4 2 REPLACING THE MEMBRANE SWITCH The membrane switch is affixed to the Top Housing ofthe scale To replace the Membrane Switch the scale must be disassembled to gain access to the switch connections 1 Refer to Section 4 1 and remove Top Housing CAUTION Use care in the next step as the Membrane Switch wiring is attached to the PC board 2 Place the scale in the upright position and carefully lift the Top Housing from the Base Housing about 50 8 mm 2 inches to 76 2 mm 3 inches Reach under the Top Housing from the front and carefully disconnect the flexible cable from connector J2 on the Main PC board 3 Onthe Top Housing lift up the defective Membrane Switch if necessary carefully prying it up with a knife and gently peel it off the upper housing 4 Carefully clean the Top Housing membrane switch area removing all traces of adhesive The best method is to use a flat razor blade 5 Insert the cable from the new Membrane Switch through the hole in the Top Housing Pee
35. on backs up step in the menu A 3 CAPACITY The capacity function allows the setting of either 3 kg 6 kg or 15 kg full scale capacity 10 match the installed Load Cell 1 Press and hold the TARE and G N T buttons together for at least 10 seconds SERVE is displayed When the buttons are released CAP is displayed for capacity 2 Tocheckthe capacity ofthe scale press the ON ZERO Off button 3 kg is displayed andis blinking 3 To change the capacity of the scale to match the Load Cell press the No button repeatedly until the correct capacity reading is displayed then press the Yes button to accept GEO is now displayed A APPENDIX A SERVICE MENU A 4 GEOGRAPHICAL ADJUSTMENT FACTOR This menu item is used to allow entry of values from O to 31 and is used to compensate for slight variations in gravity at different geographical locations around the world Complete Geographical Adjustment Factors are listed in Table A 1 The default Geo factor is 19 for Europe and 16 for USA This feature allows authorized personnel to accurately calibrate the scale at a location other than the location where the scale is to be used Prior to calibration the Geo factor is set to correspond to the geographical location where the calibration is being performed Following calibration the Geo factor is changed to match the location where the scale is used If required the scale may also be sealed according to the required approval regulations 1 Wi
36. on the bottom of the Frame assembly 10 Re install the four screws holding the Load Cell Assembly to the Base Housing See Figure 4 3 for screw locations 11 Install connector to J1 on the Main PC Board 4 5 1 Overload Protection Stop Adjustment When a Load Cell has been replaced in the existing Load Cell frame the Overload Protection Stops must be setfirst before calibrating ortesting the scale This will require the use of mm feeler gauges ranging from 0 35 mm to 2 1 mm or inch feeler gauges 0 013 in to 0 082 in See Table 4 2 1 2 At each Overload Stop Protection location insert the proper feeler gauge as specified in Table 4 2 With the correct feeler gauge positioned in the first Overload Protection Stop press down on the Frame and see if there is movement of the frame Adjust the Overload Protection Stop until there is no movement with the feeler gauge inserted The resulting gap should be the thickness of the feeler gauge 4 6 CHAPTER 4 REPAIR PROCEDURES 4 5 1 Overload Protection Stop Adjustment Cont 3 Repeat this procedure for all of the Overload Protection Stops using the appropriate feeler gauges 4 When the initial gap setting have been made recheck all gap settings and adjust as required 5 Using a thread locking solution coat all down stop screws so they will not move TABLE 4 2 LOAD CELL OVERLOAD PROTECTION STOP GAP SETTINGS CAPACITY LONG ARM MID SHORT ARM 3 kg 0 9mm 0 035 in 0 35mm 0 013 in 0
37. on the manufacturer 3 12 CHAPTER 3 SCALE TESTING AND CALIBRATION 3 8 CALIBRATION NOTE Before calibrating the scale make sure it is not set for Legal For Trade operation Calibration Types The FD Series calibration can be adjusted in two ways Span and Linearity Span calibration uses two calibration points to adjust the sensitivity ofthe scale Linearity calibration uses three calibration points to correct for non linear weighing results Calibration Weights Before beginning calibration make sure that the required calibration weights are available The model specific calibration points are listed in the table below 3 8 1 Calibration Points TABLE 3 5 CALIBRATION POINTS Model Calibration Unit Span Calibration Points Linearity Calibration Points FD3 kg 1 20r 3 kg 1 or 2 and 3 kg Ib 2 bor 6 Ib 2 or 4 and 6 Ib FD6 Kg 2 bor6 kg 2 or 4 and 6 kg Ib 5 10 or 15 Ib 5 or 10 and 15 10 FDI5 Kg 5 10 or 15 kg 5 or 10 and 15 kg Ib 10 20 or 30 Ib 10 or 20 and 30 Ib NOTES 1 Default calibration points are shown in bold print 2 Calibration Units kg or Ib are selected in the Setup sub menu 3 ASTM Class 4 or OIML Class F2 weights are required for calibration 3 8 2 Span Calibration 1 Enter the menu by holding down the Menu button until Menu is displayed When the button is released CAL is displayed 2 Press Yes to enter the Span menu 3 With SPAN displayed press the Yes butt
38. on to begin the Span calibration process 4 Clear the pan if prompted to do so then press the Yes button 5 The display will show C followed by the span calibration weight value 6 If desired press the No button to change to an alternate span calibration weight value 7 Place the indicated calibration weight on the scale and press the Yes button 8 The display will show C then done and then revert to weighing Remove the calibration weight NOTE The calibration procedure can be canceled at any time by pressing the Exit button or turning the scale off 3 13 CHAPTER 3 SCALE TESTING AND CALIBRATION 3 8 3 Linearity Calibration l Enter the menu by holding down the Menu button until Menu is displayed When the button is released CAL is displayed Press the No button to advance to the Linearity calibration menu When LIN is displayed press the Yes button to begin the linearity calibration process Clear the pan if prompted to do so then press the Yes button The display will show C followed by the first calibration weight value If desired press the No button to change fo an alternate first calibration weight value Place the indicated calibration weight on the scale and press the Yes button The display will show C followed by the second calibration weight value Place the indicated calibration weight on the scale and press the Yes button 10 The display will show C
39. ons in Appendix A 10 Turn the scale off then on It will go through all the self testing 11 After repair perform operational test see Section 3 6 If possible setthe original customer settings back into the scale 4 5 CHAPTER 4 REPAIR PROCEDURES 4 5 REPLACING THE LOAD CELL COMPONENT This procedure is used when it is desired to keep the existing Load Cell Frame and just replace the Load cell The Load Cell Assembly is centrally located inside the scale When the new Load Cell is mounted to the existing Frame the Overload Protection Stops must be adjusted l 2 9 Refer to Section 4 1 and remove Top Housing Remove connector from J1 on the Main PC Board Remove the four screws holding the Load Cell Assembly to the Base Housing See Figure 4 3 for screw locations Lift the Load Cell Assembly out of the bottom housing On top of the Load Cell Frame remove the 2 screws holding the Load cell On the bottom of the Load Cell Frame remove the 2 screws holding the Load Cell Remove the cable clamp holding the Load Cell cable on the bottom of the Frame assembly Install the new Load Cell using the 4 screws previously removed Torque the screws as indicated in Table 4 1 Make sure the Load cell is properly aligned TABLE 4 1 LOAD CELL SCREW TORQUE INFORMATION CAPACITY TORQUE 3 kg 7 N m 62 in Ib 6 kg 10 N m 88 in Ib 15 kg 10 N m 88 in Ib Re Install the cable clamp holding the Load Cell cable
40. readings To determine the repeatability perform the following test 1 Zero the scale The reading on the display should be Okg 2 Select a test weight near the maximum capacity of the scale and place it on the center of the pan Observe and record the reading 3 Remove the test weight The reading should return to Og 4 Repeat this test for ten readings Calculate the standard deviation of the ten load readings using a calculator with statistical capabilities or use the following formula Standard Deviation E o all n X weight reading in kg X Mean average of 10 readings n number of readings A worksheet has been provided for entering the data and calculation results for the Standard Deviation Figure 3 4 Step by step instructions for calculating the standard deviation are provided in Figure 3 5 and a sample calculation is provided in Figure 3 6 3 8 CHAPTER 3 SCALE TESTING AND CALIBRATION 3 6 2 Repeatability Test Cont Figure 3 4 Standard Deviation O Worksheet Reading Weight kg Weight Mean Weight Mean 2 3 4 5 6 7 8 9 10 SUM SUM Mean SUM 10 Variance SUM 9 Mean y Variance O Figure 3 5 Calculation of Standard Deviation 6 Reading Weight kg Weight Mean Weight Mean 1 3 4 2 3 4 3 3 4 4 3 4 5 3 4 6 3 4 7 3 4 8 3 4 9 3 4
41. th GEO displayed press the Yes button the current Geographical location is displayed and blinking for example GEO 19 2 Locate the Geographical Factor in Table A 1 A number from O to 31 is selected 3 Tochange the Geographical factor press the No button until the desired GEO Factor is displayed then press the Yes button CAL is now displayed A 5 SERVICE CALIBRATION Service calibration is used when span or linearity calibration fails or whenever a Load Cell or PC Board has been changed Using this procedure establishes a new set of parameters for the scale and new calibration data 1 With CAL displayed press the Yes button CLEAR PAN is displayed and blinking 2 Remove any material from the Pan and press the Yes button C is now displayed 3 After a few seconds PLACE n kg blinking where n is the first calibration weight 4 Placethe requested weight on the Pan and press the Yes button C is momentarily displayed followed by PLACE n kg where n is the second calibration weight b Placethe requested weights on the Pan and press the Yes button C is momentarily displayed followed by DONE Within a few seconds the scale returns to a weighing mode and displays the current weight on the Pan 6 Remove the weights from the Pan A 2 APPENDIX A SERVICE MENU A 6 RAMP Ramp is used to primarily determine if the Load Cell is damaged from causes including abuse heavy weights dropped on the Pan or
42. to Section 3 2 and test the Mem brane Switch Replace if necessary See Repair Procedure 4 2 Main PC Board is defective If the scale fails to turn on with a new Membrane Switch the Main PC Board should be tested in accordance with section 3 4 The Main PC Board if defective should be replaced See Re pair Procedures 4 3 After repair per form Operational Tests in Section 3 6 2 1 CHAPTER 2 DIAGNOSIS TABLE 2 2 SCALE WILL NOT TURN ON USING BATTERY POWER SYMPTOM PROBABLE CAUSE REMEDY Scale will not turn on using battery power Battery discharged or de fective Wiring harness defective or battery clips connection broken Membrane Switch defec tive Main PC Board is defec tive Refer to Section 3 5 and test the battery Replace if necessary See Repair Proce dure 4 6 Refer to section 4 1 and open the scale Check voltage at battery contacts first Check dc voltage at pins 1 and 3 of battery connector on the Main PC Board See Figure 3 2 Voltage should read approximately 6 Volts dc minimum If voltage is not present at the connector disconnect the leads from the battery and make a continuity test between the connectors on the Harness to connector pins 1 and 3 on the Main PC Board Resistance should be O ohms for the red lead and O ohms for the black lead If an open condition exists replace wiring as necessary If OK proceed Refer to Section 3 2 and test the M
43. ts replace PCB Error 14 At power up the load cell Remove load from pan if problem per signal is outside the allow sists refer to Table 2 5 and follow the able limit remedies under Load Cell Damaged Zero range error 2 9 CHAPTER 2 DIAGNOSIS 24 FD SERIES SCALES ERROR CODE TABLE Cont The FD Series Scales is equipped with software which will display an error condition when it occurs Review the listed codes and follow instructions 10 correct the problem TABLE 2 7 FD SERIES SCALES ERROR CODES bration error Load cell damaged PC board damaged ERROR CODE CAUSE REMEDY Error 21 Checksum error Check menu settings User data menu settings Corrupt checksum error Perform Service calibration See Appen calibration dix A Service Menu CAL E Incorrect weight used Cali Calibrate using correct calibration weights and in the correct order Refer to Section 3 3 and test the Load Cell If defective replace the load cell see Repair Procedures 4 4 and or Test the Main PC board refer to Section 3 4 If defective see Repair Procedure 4 3 After repair perform Operational see Section 3 6 2 6 CHAPTER 3 SCALE TESTING AND CALIBRATION 3 TESTING AND CALIBRATION This section of the manual contains testing procedures of the individual replaceable components and the scale Before and after servicing the FD Series Scales an operational test and various performance tests should
44. y 0 001 kg 0 002 kg 0 005 kg Linearity 0 001 kg 0 002 kg 0 005 kg Off Center Load 0 001 kg 0 002 kg 0 005 kg Weighing units g kg Ib oz decimal fractional Ib oz decimal fractional oz Weight display 5 digit 19 mm high digits 7 segment back lit LCD display with fractional ounce and battery status indicator Keyboard 4 button membrane switch Application modes Weighing Checkweighing Checkweigh indication 3 LEDs yellow green red with configurable alert beeper Power 9 VDC 0 5A AC Adapter Internal rechargeable sealed lead acid battery Typical battery life 120 hours with 15 hour recharge time Tare range To capacity by subtraction Stabilization time Within 2 seconds Auto zero tracking Off 0 5 1 or 3 divisions Operating temperature range 10 C fo 40 C 14 F to 104 F Storage temperature range 40 C to 70 C 40 F to 158 F Approved temperature range 0 C to 40 C 32 F to 104 F Protection IP43 Construction 304 Stainless steel housing and platform Pan size DXW 209 x 209 mm 8 2 x 8 2 in Scale dimensions DxWxH 300 x 223 x 71 mm 9x 12x 2 8 in Shipping dimensions DxWxH 400 x 320 x 185 mm 15 8 x 12 6 x 7 3 in Scale weight 3 6 kg 8 0 Ib Shipping weight 5 kg 11 Ib NOTE Product specifications are subject to change without any obligation
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