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Service Manual - Test Equipment Depot

1. 00s222200002200000RBnnnnnn nennen nennen 3 44 Cemeng PNS seen 3 44 Centering PINS INStall SG ur ee ee ea 3 44 Contact Board LOCION resns err E NR umes dates 3 45 Contact Board with cover holder off ccccccsseeceeeeeeeeeeeeeeeeeeseeeeeeseeeeeeseeeeees 3 45 Loosening Ratio Beam NUTS an ee 3 45 Ratio Beam Screws and Washers reMOved 00ccccceeeeeeeeeeeeeeeseaeeeeesaeeeeessanees 3 45 Loosening InCal Weight Arm NnUts ccccccsssseeeeceaeseeeeececeeeseeeesesaaseeeeeeeneneaes 3 46 Weight Arm Screws and Washers removed uuusssnssnnenennnennnnneennnennnnee nennen 3 46 MEalWeightArmremoval Seelen 3 46 InCal Weight Arm removed ccccecccccssseceeceeseeeeeseseeeseeeseeeeseaeeeessegeeeessageeeeenes 3 46 Aluminum Sleeves removed u00224000200000nennnennnnnn nennen nenne nnnnnnennnnnen nennen 3 47 UB DoWwn SIOD ScteW a n ehe 3 47 amp enterind PINS removed eek 3 47 REMOVING the Ratio Beam a Maleate 3 47 Ratio Beam Removed nie a r ae E E 3 47 Removing the Ratio Beam 22uu022u000snnennnnnnnnnnnnnnnennnnnnnnnnn nenne neuen nnnnnn nenne nennen 3 47 Ratio Beam BREMoVved unnnn ee 3 47 Removing the Aluminum Sleeves uo2uuussssnseennnnnnnnnnnnnnennne nennen nennen nenne nennen 3 47 Ratio Beam Weight Removal nn ueh eid Bacbieesieds 3 48 Load Gell Gritieal Area een R R 3 48 Magnet Aro aneignen 3 48 Ratio Beam Vane Slotted Area uuss2222uussnnnnnnennnnnnennn
2. u 222002220022nne nennen 3 20 Cable connects to the Position Sensor Board u0002222000020nnne nennen 3 21 On Analytical balances the 3 screws securing Load Cell are on botton 3 21 Service Fixture screws and shims for Analytical balances 3 22 Bottom Mounting Plate and Flexure Arms Analytical balance s Load Cell 3 22 Top Mounting Plate and Flexure Arms Analytical balance s Load Cell 3 22 FIGURE NO 3 58 3 59 3 60 3 61 3 62 3 63 3 64 3 65 3 66 3 67 3 68 3 69 3 70 3 71 3 72 3 73 3 74 3 5 3 76 3 7 7 3 78 3 79 3 80 3 81 3 82 3 83 3 84 3 85 3 86 3 87 3 88 3 89 3 90 3 91 3 92 3 93 3 94 3 95 3 96 3 97 3 98 3 99 3 100 3 101 3 102 3 103 3 104 3 105 3 106 TABLE OF CONTENTS LIST OF ILLUSTRATIONS TITLE Page No Screws removed from Bottom Mounting Plate inserted into the Hanger 3 23 Shims are inserted between the Hanger and the Load Cell 3 23 Analytical balance Load Cell with Top Bracket visible ccccccsscceseeeeeeeeeees 3 23 Vertical Flexure and screws Lock Plate washers and bushings removed 3 23 TOD Flex re Ann Analytics ei 3 23 Bottom Flexure Arm AnalytiCal ccccccsscccsceseeeceeseceeeseeeeseeeseueeseeesaueeseesaaes 3 23 Hanger WITN TWO SClEWS a ee ONAN 3 25 Service Fixture attached to the front of Load Cell after removin
3. i Figure 3 1 Top panel lifts up and slides out Figure 3 2 Groove in side panel s door guide aligns with tab on Housing 2 Remove the Weighing Pan For a balance without a Draft Shield 1 Remove the Weighing Pan and Pan Support After completing the preliminary steps turn the balance over and remove two screws from the rear and one near the front under a plastic sliding tab Lift off the Top Cover Then lift off the Load Cell cover You now have access to all components of the balance 3 2 Pioneer Balances Service Manual CHAPTER 3 MAINTENANCE PROCEDURES 3 3 LOAD CELL REMOVAL AND DISASSEMBLY The Load Cell may need to be removed and repaired because of balance instability or because the balance does not calibrate or repeat or because the balance is physically broken or displays an error code The ratio coil may have a short circuit Possible causes of Load Cell problems include parts being misaligned bent or broken Flexures contamination or debris or in any moving part 3 3 1 Variations in Pioneer Load Cells Pioneer balances have different types of Load Cell Use the illustrations below to identify the type used in the balance being serviced Precision amp Analytical Load Cells have different style Flexure Arms Figure 3 3 Precision Load Cell with InCal Figure 3 4 Analytical Load Cell with InCal Section 3 3 2 p 3 5 Section 3 3 6 page 3 7 Figure 3 5 Precision Load Cell Figure 3 6 Ana
4. CHAPTER 3 MAINTENANCE PROCEDURES 3 3 32 Installing the InCal Weight Arm Note Not all block style Load Cells have a Weight Arm as shown Ifthe Load Cell does not have this style Weight Arm proceed to Step 7 and insert second Centering Pin 1 Carefully slide the InCal Weight Arm into position See Figures 3 146 and 3 147 InCal Weight Arm Figure 3 146 InCal Weight Arm before insertion Figure 3 147 Inserting InCal Weight Arm 2 Be sure the notch at the end of the Weight Arm aligns with the pin inserted in Step 7 on the previous page through the Ratio Beam s screw holes 3 Genily lift the Ratio Beam and insert a second Centering Pin in the InCal Weight Arm near the Magnet See Figure 3 148 A N 4 Do not use tools in this step Install the screws washers and nuts for the InCal Weight Arm Work gently to avoid stressing the TN InCal Weight Arm Load Cell s internal flexures a inn 5 After installing the screws washers and nuts by hand hold the screw head with a screw driver while amp 7 Hold Screw tightening the nuts for the InCal Weight Arm See Figure 3 149 Figure 3 149 Proper method for tightening nuts while holding screw head stationary CHAPTER 3 MAINTENANCE PROCEDURES 3 3 32 Installing the InCal Weight Arm 6 10 11 N Remove the pin securing the InCal Weight Arm at the Magnet end Centering Pins Insert the pin just removed into the hole below
5. Figure 3 6 The Vane removed Figure 3 66 The Vane is secured by two screws CHAPTER 3 MAINTENANCE PROCEDURES 3 3 16 Disassembling Analytical Load Cells 16 Unsolder the two white wires connected to the Position Sensor Board Then remove the two inset screws that secure the board to the Load Cell Carefully lift the Position Sensor Board away from the Load Cell See Figure 3 68 T podio a a a holes for removing the Position Sensor Board Contact Board with 3 wire cable attached Figure 3 69 Contact Board with 3 wire ribbon cable soldered to it 17 Unsolder the three points of the 3 wire ribbon cable that connect to the Contact Board at the rear of the Load Cell See Figure 3 69 18 Use an ohm meter to measure resistance from the middle wire to each side wire The readings should be approximately equal at around 400 460 ohms The resistance from any wire to the frame should be open or infinity If any resistance is measured the Ratio Beam must be replaced 19 Remove the four screws that secure the Magnet Half See Figure 3 70 Grasp the Magnet Half from the top and lift it out It may be necessary to pull hard to overcome the magnetic force as well as possible resistance caused by corrosion Figure 3 70 Four screws secure the Magnet Figure 3 71 The Magnet Half when Half to the Ratio Beam removed should be cleaned CHAPTER 3 MAINTENANCE PROCEDURES 3 3 16 Disassem
6. ee C 1 C 2 The Software Service Tool s Restore EEProm Tab cccccsseeeeeeeeeeeeeeeeeeeeeees C 2 C 3 The Software Service Tool s Replace Load Cell Tab uuussnussneenneenneenennen C 3 C 4 The Software Service Tool s Replace PCB Tab cccceccceecsseeeeesseeeeeeeeeeeeeeens C 4 C 5 The Software Service Tool s Download Software Tab cccccecssseeeeeeeeeeeeeens C 5 C 6 The Software Service Tool s Diagnostics Tab ccccccsseseeeeseeeeeeeseeeeeesaeeeeeeas C 6 TABLE OF CONTENTS CHAPTER 1 GETTING STARTED 1 1 INTRODUCTION This service manual contains the information needed to perform routine maintenance and service on the Ohaus Pioneer Precision and Analytical balances The contents of this manual are contained in five chapters Chapter 1 Getting Started Contains information regarding service facilities tools and test equipment measuring masses specifications and the mechanical and electronic functions of the balance Chapter 2 Troubleshooting Contains a diagnosis diagnostics chart and error code table Chapter 3 Maintenance Procedures Contains preventive maintenance procedures and disassembly repair and replacement procedures Chapter 4 Testing Contains an operational test segment display test performance tests and adjustments Chapter 5 Drawings and Parts Lists Contains exploded views of Pioneer balances and Load Cells identifying all serviceable compo
7. 2 Clean the outside of the balance using a damp cloth with warm water CAUTION A N DO NOT USE CHEMICAL CLEANERS OR SOLVENTS OF ANY TYPE SOME CLEANERS ARE ABRASIVE AND MAY AFFECT THE BALANCE S FINISH 3 Check the Power Cord for broken or damaged insulation 4 Make a visual inspection for faulty connectors wiring and loose hardware 3 2 OPENING THE BALANCE Opening the Pioneer balance varies slightly according to the specific model as detailed below Differences are detailed in the text Use these procedures in order to Replace Printed Circuit Boards Replace bent or broken Flexures Gain access to the Load Cell for removal cleaning parts replacement and alignment Pioneer Balance Service Manual 3 1 CHAPTER 3 MAINTENANCE PROCEDURES 3 2 1 Variations in Opening Pioneer Models Turn the balance off and unplug the power cord before you begin Preliminary Steps For a balance with a Draft Shield 1 Remove the Draft Shield components from the balance Remove the top panel lift its plastic handle and slide it forward to remove it See Figure 3 1 Remove the side doors when they are closed a groove in the plastic door guide aligns with the tab on the Housing See Figure 3 2 Align the groove and lift the panel straight up then out and down to disengage it from the top To remove the front and back panels press on the tab in the middle of the top frame and gently press the panel out
8. Board on the Load Cell frame Be extremely careful not to stress or break the fine wires attached to the Contact Board 8 Glue the Contact Board to the Figure 3 41 Contact Board frame as in Figure 3 41 9 Attach the Position Sensor Board to the Load Cell frame using three screws See Figure 3 35 The left side screw goes in the outside hole It has no washer The two right side screws both have washers Install screws finger tight so the board can be moved for adjustment in Step 17 below 10 Solder the 3 wire Ribbon Cable to the Contact Board See Figure 3 41 11 Solder the two small wires to the solder points on the bottom of the Position Sensor Board and the two on the top The two on the bottom must be re soldered in the same positions as pictured in Figure 3 42 white on left red on right The two wires on the top connect to the Temperature Sensor Their order is not important Figure 3 42 Solder points on Position Sensor Board Ohaus Corporation www ohaus com 3 16 Pioneer Balances Service Manual CHAPTER 3 MAINTENANCE PROCEDURES 3 3 11 Load Cell Reassembly Precision Balances 12 Install the Bottom and Top Flexure Arms in that order Flexure side down See Figures 3 43 and 3 44 Avoid bending the Flexures If bent they must be replaced Screws securing Flexure Arms Figure 3 43 Precision Load Cell top 13 Install the Vertical Flexure Ratio Bear Vertical Ratio Bea with the elonga
9. IS Remove the mass from the Pan ALAA J 17 Q flashes as the balance calibrates a zero 51 setting a A 4 The specified middle weight flashes Place the indicated weight in the center of the Pan ar PS anf ite i gt q Na A p aal Busy flashes After a few seconds Clear Pan flashes Remove the mass from the Pan S rs Ww ef A The specified maximum weight flashes J Place the indicated weight in the center of the Pan N D w aal N p gt aal a IS l Busy flashes After a few seconds Clear Pan flashes 93 u Remove the mass from the Pan N 4 ir Q flashes as the balance re calibrates the zero 7 setting o j When calibration finishes Done appears briefly and the 1 E balance returns to weighing mode LUIS Note A N Be careful not to touch the scale or the table while calibration is in progress as it will cause the process to fail APPENDIX B SERVICE CALIBRATION APPENDIX B SERVICE CALIBRATION This section describes the Service Menu and sub menus which allow authorized service personnel to perform factory calibrations B 1 Entering the Service Menu Turn the balance off Enter the Service Menu by pressing and holding I 1i ed ol On Zero Off and Unit together As the balance powers y ja U sZ up SERVICE appears followed by RAMP aA _ ar Press Yes to select Ramp nn o Press No to advance to Span Calibration s7 far 0 je B 2 Ramp T
10. Insert and tighten the two remaining Figure Se Adjust Position Sensor Board vertically until Err8 X does not appear screws to secure the Load Cell Check again that an Error 8 X is not displayed If so repeat Step 9 12 Disconnect the power Install the Load Cell Cover and close the balance CHAPTER 3 MAINTENANCE PROCEDURES 3 3 18 Reassembling Analytical Load Cells Before reassembly take the following maintenance steps e Be sure all Flexures are straight or replace them with new ones e Be sure the hole in the Vane is clear and that the Vane is free of debris e Be sure the Magnet is clean and free of debris Reassemble the Load Cell by following these steps 1 Carefully insert the Ratio Beam into the Load Cell frame Adjust the black Up down Stop Screw so the Ratio Beam can clear See Figure 3 77 Figure 3 78 Service Fixture is installed prior to installing Ratio Beam Flexures 2 Install the Service Fixture 3 Adjust the Up down Stop Screw so the groove is half way above and below the stop tab Close it completely then open it completely counting turns then close it half way 4 Position the Sideways Motion Stop Plate so the small post in the Ratio Beam is centered in the hole in the Plate Then insert and tighten the two screws See Figure 3 78 Screw holding Contact Board Up Down Stop Screw 5 Install the Ratio Beam Flexures with a A C elongated hole down Each screw rn has
11. 1 for specified masses for all Pioneer models Masses must meet or exceed ASTM Class 1 or OIML E1 Tolerance Calibration masses are available as accessories from any Ohaus dealer A 2 Span Calibration With the balance on press and release Unit Menu until I Id J CAL appears Press Yes the On Off button J ST f o a gt 4a SPAN appears Press Yes dul alt SOT The specified mass weight flashes LWW Pressing No will toggle to alternate mass weight WILLS Place the indicated weight in the center of the Pan oe Busy flashes After a few seconds Clear Pan flashes 1411 Remove the mass from the Pan n 4 7 Q flashes as the balance calibrates a zero Td setting o ace T oe When calibration finishes Done appears briefly and the r Tag balance returns to weighing mode II NOTE If calibration fails ensure that the test area is free from drafts and the surface the balance rests on is level and free of vibrations Then try to calibrate again If it continues to fail there may be an internal problem To resolve internal problems follow procedures in Chapter 3 APPENDIX A STANDARD CALIBRATION A 3 Linearity Calibration With the balance on press and release Unit Menu until Im CAL appears Press Yes the On Off button J 7 J Oo a gt 4a SPAN appears Press No Linear appears Press Yes J ad 0d If PUSH flashes place maximum weight on the Pan Aa MAIDINN After a few seconds Clear Pan flashes w T S
12. 2 1 CHAPTER 2 DIAGNOSTIC GUIDE 2 2 1 Diagnosis SYMPTOM Balance will not turn on with AC adapter supplied Balance does not respond to front panel controls Poor accuracy Balance can be turned on but will not calibrate manually TABLE 2 1 DIAGNOSTIC GUIDE Main power source is off Adapter defective Input connector at rear of Balance may be defective Main PC Board defective Main PC Board is defective Unstable environment Balance out of calibration Balance was not re zeroed before weighing Incorrect weights Balance not level Balance is unstable Load cell assembly defective PCB is defective 2 2 PROBABLE CAUSE REMEDY Check the main power source outlet for proper voltage Check the AC adapter voltage output which should match the specified voltage on the adapter If voltage is low or nonexistent replace the AC adapter If OK proceed Open the balance Leave the cable connected to the Top Housing Reconnect the AC adapter Check AC voltage at the input connector terminals It should read 12 V AC If voltage is not present replace the input connector If OK proceed Replace the Main PC Board Replace the Main PCB Move balance to suitable location ensure that balance is level Calibrate the balance Press gt O T lt with no weight on the pan then weigh item Verify that proper weights are used Level the balance Perform Automatic Internal Calib
13. Load Cell using the six screws supplied with the Fixture tighten screws finger tight until completing next step See Figures 3 21 and 3 22 Ratio Beam Flexures Ratio Beam Flexures 923345 975389 Figure 3 21 Service Fixture for 150g to Figure 3 22 Service Fixture for 510g to 4100g 410g Precision Load Cell attached to Precision Load Cell attached to Hanger Ratio Hanger Ratio Beam and Load Cell frame Beam and Load Cell frame 3 8 Pioneer Balances Service Manual CHAPTER 3 MAINTENANCE PROCEDURES 3 3 8 Load Cell Disassembly Precision Balances 2 Loosen do not remove the two screws shown in Figures 3 19 and 3 20 that secure the top and bottom Flexure Arms at the end closest to the Position Sensor Board Flexure Arm Screws closest to Position Sensor I 3 Remove the two screws and washers that secure the Vertical Flexure and remove the Vertical Flexure 4 Remove the two screws and washers that secure each Ratio Beam Flexure and remove the Flexure 5 Remove the four screws and washers on the Top Flexure Arm and remove it Don t loosen the screws that secure the Flexure to the Flexure Arm 6 Turn the Load Cell over and remove the four screws and washers on the Bottom Flexure Arm Carefully remove it NOTE A When handling the Flexure Arms do not bend the Flexures 7 Carefully examine each Flexure to see if it is bent See Figure 3 23 If uncertain place the Flexure on
14. Mechanism Verify that all other functions are operational If functions are OK the Main PC board is defective Test the balance for proper functions and calibration Use Units menu to set desired units CHAPTER 2 DIAGNOSTIC GUIDE 2 3 ERROR CODES When a problem occurs using the balance the display will indicate an error code Table 2 2 describes the various error codes and specifies the probable cause and remedy TABLE 2 2 ERROR CODES ERROR PROBABLE CAUSE REMEDY Average Piece Weight too small Add additional samples Err 7 0 Time out after delay in Power on Press Off then press On or menu item selection Perform Troubleshooting measures See Section 2 1 1 Err 8 1 Pan has load during power on Remove weight from Pan and re zero Perform Troubleshooting steps Err 8 2 Pan was removed prior to power Install Pan and re zero on Perform Troubleshooting steps Err 8 3 Weight on Pan exceeds Remove weight from Pan Capacity Perform Troubleshooting steps Err 8 4 Pan was removed during Re install Pan weighing Perform Troubleshooting steps Err 9 5 Factory calibration data Perform Service Calibration corrupted See Appendix B Err 9 8 Factory calibration data Perform Service Calibration corrupted See Appendix B Error 53 Cable from Load Cell to Main Replace cable PCB disconnected or damaged EEPROM Checksum error Restore EEPROM See Appendix C REF Err Reference weight is too small Add additional sa
15. ROUND PAN BALANCE HOUSING amp PARTS Precision Round Pan Balance Housing amp Parts Precision Round Pan Balance Housing amp Parts Figure 5 1 CHAPTER 5 PARTS LISTS amp DIAGRAMS 5 1 PRECISION ROUND PAN BALANCE HOUSING amp PARTS TABLE 5 1 PRECISION ROUND PAN BALANCE HOUSING amp PARTS Leveling Feet 2 Liquid Crystal Display LCD For all Pioneer Models see specific parts lists through your Ohaus distributor CHAPTER 5 PARTS LISTS amp DIAGRAMS 5 2 PRECISION ROUND PAN INCAL BALANCE HOUSING amp PARTS Precision Round Pan InCal Balance Housing amp Parts Figure 5 2 Precision Round Pan InCal Balance Housing amp Parts CHAPTER 5 PARTS LISTS amp DIAGRAMS 5 2 PRECISION ROUND PAN INCAL BALANCE HOUSING amp PARTS TABLE 5 2 PRECISION ROUND PAN INCAL BALANCE HOUSING amp PARTS Leveling Feet 2 Load Cell 5a Traditional MFR 5b Block Style Liquid Crystal Display LCD For details on Load Cell and InCal Mechanism parts see Section 5 6 CHAPTER 5 PARTS LISTS amp DIAGRAMS 5 3 PRECISION SQUARE PAN INCAL BALANCE HOUSING amp PARTS Precision Square Pan InCal Balance Housing amp Parts Figure 5 3 Precision Square Pan InCal Balance Housing amp Parts CHAPTER 5 PARTS LISTS amp DIAGRAMS 5 3 PRECISION SQUARE P
16. RS232 Cable and Power Cable 2 Remove the screws on the Main PC Board which secure it to the Base 3 Install replacement Main PC Board in the reverse order as removed Check the LCD display on the new board and remove the protective plastic covering if in place 4 Reassemble the balance 5 Complete the PCB installation using the Pioneer Software Service Tool see Appendix C 3 Install New Main Printed Circuit Board 6 After assembly verify that the balance meets all specifications See Chapter 1 Perform all tests See Chapter 4 3 14 Pioneer Balances Service Manual CHAPTER 3 MAINTENANCE PROCEDURES 3 3 11 Load Cell Reassembly Precision Balances Before re assembly take the following maintenance steps Be sure all Flexures are straight or replace them with new ones Place each Flexure on a clean flat surface and check that both sides rest evenly on the surface If a Flexure is bent even slightly it must be replaced See Figure 3 23 Be sure all parts are clean and free of debris 1 Adjust the black Up Down Stop Screw so the Ratio Beam can clear 2 Insertthe Ratio Beam into the Load Cell frame See Figure 3 36 3 Install the Service Fixture and u Sl Hanger to the frame and the Ratio m Beam Hold the Hanger by hand Figure 3 36 Installing Ratio Beam while inserting the two screws that clearing the Up Down Stop Screw secure the Fixture to the Hanger Then insert the four screws tha
17. See Section 3 3 11 12 Turn Auto Zero back to On in Menu Setup CHAPTER 4 TESTING 4 4 6 Repeatability Test Repeatability is the Standard Deviation of a set of similar weight readings Requirements To perform this test a single mass must be used for all readings The test mass should be approximately 1 2 of the capacity of the instrument Wear gloves when handling the mass Before starting a repeatability test set up the instrument as follows Set Up Enter the menu and adjust and record the following settings A Set the Filter level to medium or the center of its range B Set the AZT Auto Zero Tracking to 5d or its lowest setting Do not turn it off C Set the instrument to display the same units as the performance specifications Usually kg g or mg Record Settings Filter Level Setting Auto Zero Tracking Setting Displayed Units Mass Used TEST PROCEDURE 1 Zero the instrument if it does not read zero 2 Using atest mass approximately half the capacity of the instrument place the mass on the center of platform Record the reading on the worksheet provided 3 Remove the mass from the platform Repeat this test starting at Step 1 until you record a total of ten readings Fill in the worksheet Table 4 4 with the ten 10 readings CHAPTER 4 TESTING 4 4 6 Repeatability Test TABLE 4 4 REPEATABILITY WORKSHEET Tg Te Delta Reading Mean Delta x Delta n number of Readi
18. a clean flat surface and check that both sides rest evenly on the surface If a Flexure is bent even slightly it must be replaced Figure 3 23 Bent Flexure Pioneer Balance Service Manual 3 9 CHAPTER 3 MAINTENANCE PROCEDURES 3 3 8 Load Cell Disassembly Precision Balances 8 11 12 Unsolder and remove the four wires shown in Figure 3 24 The two wires at the bottom connect to the light source They must be re soldered as pictured here white on left red on right The two wires on the top connect to the Temperature Sensor Their positions are not important Screws holding Remove the three screws holding the Position Sensor Board Position Sensor Board in place The two on the right have washers The one on the left doesn t Figure 3 24 Position Sensor Board Gently set the Position Sensor Board aside avoid putting stress on the 3 wire ribbon cable which is soldered to the Contact Board If the Ratio Beam is to be removed unsolder the 3 wire ribbon cable from the Contact Board See Figure 3 25 Wires glued to post on Ratio Beam Contact Board glued to frame Figure 3 25 Contact Board with ribbon cable Figure 3 26 Fine wires connected to the A 14 Carefully pry the Contact Board off Contact Board and affixed to Ratio Beam the Load Cell frame and tape it to the Beam Take care not to stress or break the fine wires connected to the Contact Board If they are bro
19. for Block Style Load Cells PN 476000 030 CHAPTER 3 MAINTENANCE PROCEDURES 3 3 22 Internal Calibration Testing This section describes how to test the internal calibration in a Block Style Load Cell There can be several reasons that internal calibration does not function including a broken or jammed InCal Mechanism a defective InCal Motor or a defective Main PC Board To test the internal calibration proceed as follows 1 Connect an RS232 cable and a computer to the balance 2 Follow instructions in Appendix C Section C 5 1 Incal Weight Mechanism Testing 3 Observe the motion of the InCal Weight when you press Raise or Lower If the weight does not move replace the InCal Motor See Section 3 3 21 4 Ifthe operation is not smooth replace the entire InCal Mechanism See Section 3 3 22 3 3 23 InCal Motor Removal amp Replacement 1 Remove the balance s Housing and Load Cell as described in earlier sections 2 Remove the two screws holding the InCal Motor and InCal Motor Shield in place from the InCal Mechanism See Figures 3 99 and 3 100 InCal Mechanisms ir InCal Motor InCal Motor Shield Mounting Screws holding om a Screws InCal Motor gt G Figure 3 99 InCal Motor Figure 3 100 InCal Motor Removal IHRE TI ar H arbe 1 3 With the Incal Weight in upper most position the Motor Coupler should be in the position shown in Figure 3 101 InCal Weight Figure 3 101 Motor Co
20. on the Magnet Figure 3 158 Pin centered in PSB 6 Install the Ratio Beam Ribbon Cable on the PCB and the Contact Board CHAPTER 3 MAINTENANCE PROCEDURES 3 3 34 Setting the Up Down Stop Screw on Block Style Load Cells This procedure is required when either the Ratio Beam has been removed or replaced or when the Position Sensor has been replaced 1 2 7 Carefully lift the Ratio Beam with Disconnect the Ribbon Cable from the Contact Board to the Load Cell PCB The Load Cell must be completely reassembled and installed in the balance Housing Plug the Ribbon Cable from the top of the Load Cell PCB into the Main PC Board Attach a Voltmeter DC range to the pins on the Load Cell PCB test connector as shown in Figure 3 159 Apply power to the balance Test Connector HE E m pe s egen ENTE Test Connector pe aa A A 1 TEN r AT Eu E Ai aris i ETIE thumb and forefinger until it is at the top of the Up Down Stop Screw Measure the voltage again If the two voltage values either side of zero are not of the same magnitude e g 2 V and 1 6 V the vertical stop must be adjusted until the values are symmetrical Maximum difference is 0 2 Volts Figure 3 161 Up Down Stop Screw To adjust the Up Down Stop Screw turn the Screw and repeat Steps 2 and 3 until the readings are within specifications See Figure 3 161 CHAPTER 4 TESTING 4 1 TESTING Before and after ser
21. power from the back of the balance then re connect 11 Perform Service Calibrations see Appendix B Test the balance APPENDIX C SOFTWARE SERVICE TOOL INSTRUCTIONS C 3 Install New Main Printed Circuit Board PCB 1 Follow steps in Sections 3 1 3 to replace the PCB Then connect the balance to your computer 2 Start the Pioneer Service Tool Software 3 Click on the tab labeled Replace PCB Pioneer Service Tool 1 00 O x File Settings Restore EEPROM Replace Loadcell Figure C 4 The Software Service Tool s Replace PCB Tab 4 Enter the Serial Number value from the label on the back of the balance 5 Enter the IDNR number xxx xx xx xxxx from the label on the back of the balance 6 Click the Start button 7 The software will indicate the download progress When complete disconnect the power from the back of the balance then re connect 8 Perform Service Calibrations see Appendix B Test the balance APPENDIX C SOFTWARE SERVICE TOOL INSTRUCTIONS C 4 Update the Software in the Balance 1 Connect the Balance to your computer 2 Start the Pioneer Service Tool Software 3 Click on the tab labeled Download Software Pioneer Service Tool 71 00 i Ioj x Fie Settings Restore EEPROM Replace Loadcell Replace PLB Mot File To Download To Scale None Selected Change Download Mot File To Scale Mot File Not Found Select New Start Download Figure C 5 The Software Serv
22. tear off then remove the Fastening Screw as shown in Figure 3 122 Hole in Ratio Beam for Contact Board 4 Remove the Contact Board from the Load Cell frame screw it on to the hole in Ratio Beam directly above it See Figures 3 122 and 3 123 Note The screw changes Figure 3 123 Contact Board with cover holder off from the lower to the upper hole on the Contact Board before inserting it into the hole on the Ratio Beam AN 5 Carefully loosen and remove the nuts on the Ratio Beam while holding the screw heads to prevent movement This is very important See Figure 3 124 Ratio Beam pod Loosen Nut F Hold Stationary Figure 3 124 Loosening Ratio Beam Nuts Figure 3 125 Ratio Beam Screws and Washers removed CHAPTER 3 MAINTENANCE PROCEDURES 3 3 31 Removing the Ratio Beam on Block Style Load Cells Note Not all Load Cells require a Weight Arm as shown Ifthe Load Cell does not have this style Weight Arm proceed to Step 9 6 Remove the screws washers and nuts holding the InCal Weight Arm See Figure 3 126 Loosen Nut Figure 3 126 Loosening InCal Weight Arm Figure 3 127 Weight Arm Screws nuts and Washers removed 7 Carefully slide the InCal Weight Arm as shown in Figure 3 128 Figure 3 129 illustrates the InCal Weight Arm removed InCal Weight Arm Figure 3 129 InCal Weight Arm removed CHAPTER 3 MAINTENANCE PROCEDURES 3 3 31 Removing the Ratio Beam on Block Style Load Cells
23. the balance calibrates a zero setting ee DS na The specified middle weight flashes Place the indicated weight in the center of the Pan M un v d Na N b v d Na N RN l Busy flashes After a few seconds Clear Pan flashes Remove the mass from the Pan ce Ps Ww Ya A The specified maximum weight flashes Place the indicated weight on the center of the Pan Busy flashes After a few seconds Clear Pan flashes Remove the mass from the Pan gt N i v a Nu D v a Da RN l The specified middle weight flashes again WISI Place the indicated weight on the center of the Pan ss LOL Busy flashes After a few seconds Clear Pan flashes eee ee Remove the mass from the Pan Q flashes as the balance re calibrates the zero 1 ag setting When calibration finishes Done appears briefly 7 7 1 EndServ appears If you have completed Service J WE Calibration press Yes Otherwise press No to cycle im 1 7 s7 vi through the Service Menu again When calibration is finished the balance returns to the weighing mode APPENDIX B SERVICE CALIBRATION APPENDIX C SOFTWARE SERVICE TOOL INSTRUCTIONS APPENDIX C SOFTWARE SERVICE TOOL INSTRUCTIONS The Pioneer Software Service Tool is used for 5 purposes 1 2 3 4 5 To restore EEPROM data after the Position Sensor Board is replaced To install a new Load Cell To install a new Main Printed Circuit Bo
24. weight is not stable This could be because the weight is not fully lowered and or because it is touching something To correct this symptom follow the procedures in Section 3 3 7 3 3 8 for Precision Load Cells Sections 3 3 12 3 3 13 for Analytical Load Cells and Sections 3 3 17 3 3 19 for Block Style Load Cells with Internal Calibration Test Equipment Depot 800 517 8431 99 Washington Street Melrose MA 02176 TestEquipmentDepot com x 8 0 2 5 1 5 3 3 P N 80251533 SERVICE MANUAL PIONEER BALANCES
25. 11 7 Re solder the Temperature Sensor Board and the Position Sensor Assembly 8 Follow instructions in Appendix C to Restore the EEPROM w rah 00 u an ag 1597 Tie 1097 zu e un Slot Mounting Screw Figure 3 113 Block Style head Cell PC Board Removed from Load Cell CHAPTER 3 MAINTENANCE PROCEDURES 3 3 30 Removing the Load Cell PCB Temperature Sensor Position Sensor Assembly The Temperature Sensor Position Sensor and the Load Cell PCB can be removed and installed as an assembly as follows Sr x r ere Ave ae tas Ar Ae d Di SATT TIME we R li Er Alte ri i x eek ot em a En Rn w Aa IF Temperature Sananr 1 Remove the three screws that secure the Position Sensor to the Magnet Lift it off gently but firmly to overcome the magnetic resistance but avoid breaking the soldered connections to the Load Cell PCB See Figure 3 115 Soldered connections to Note Do not adjust the screws Load Cell around the Temperature Sensor hole PCB It could ruin the Load Cell 2 Remove the screw on the bottom edge of magnet that secures the Temperature Sensor It has a very fine thermister extending into the hole between the three screws on the bottom of the Magnet See Figure 3 116 Don t adjust screws around Temperature Sensor hole 3 Lift out the Temperature Sensor careful to avoid stressing the wires connecting it to the Load Cell PCB Figure 3 116 Removin
26. 3 37 Mounting Screws holding InCal Mechanism 2220000222000 BR en nennen 3 37 Removing the InCal Mechanism 2224000224000BRnnnnnnnnn nennen nennen nenne nennen 3 37 InGal Mechanism Allgnment 2 2 Eee 3 38 Gentering lNnGalWeghtaseteren rien 3 38 FIGURE NO 3 107 3 108 3 109 3 110 3 111 3 112 3 113 3 114 3 115 3 116 3 117 3 118 3 119 3 120 3 121 3 122 3 123 3 124 3 125 3 126 3 127 3 128 3 129 3 130 3 131 3 132 3 133 3 134 3 135 3 136 3 137 3 138 3 139 3 140 3 141 3 142 3 143 3 144 3 145 3 146 3 147 3 148 3 149 3 150 3 151 3 152 3 153 3 154 3 155 TABLE OF CONTENTS LIST OF ILLUSTRATIONS TITLE Page No REMOVING POSITION Sensor 3 39 Rato Beam PIN AlIGHMENL ane ee 3 39 Base Plate ReEMOVAl anne E 3 40 Load Gell MOUNTING Component nee 3 41 Load Cell Aligniment 10 Base Plate ass 3 41 Block Style Load Cell PC Board Item Locations cccccceeeeeseeeeeeeeeeeeseeeesaees 3 42 Block Style Load Cell PC Board Removed from Load Cell 3 42 Load Cell PCB Temperature Sensor Position Sensor assembly 3 43 POSITION SENSO se ee ee 3 43 Removing Temperature Sensor uuuuuunessnnnennnnnennnnnnnnnnnnnnennnnnennnnnnnnnnsnnnennnnnennen 3 43 EOac OEP EB ee se ee ee Meile est 3 44 Contact Board Cover is removed by squeezing the plastic post 3 44 Contact Board with cover holder off
27. 3 for maximum allowable variance for each of the four positions CHAPTER 4 TESTING 4 4 3 Off Center Load Adjustment for Precision Models A 10 11 12 13 NOTE Do not attempt these adjustments unless the balance is free from drafts The balance is very sensitive and adjustments will be affected Set Auto Zero to Off in Menu Setup Open the balance See Section 3 1 Reinstall the Pan Plug the power cord into the balance and turn it on Place a mass that weighs the balance s full capacity on the center ofthe Pan Oo Turn in direction shown by arrows For errors Press O T the center button front to back turn both adjustments the same to tare the balance and return direction For side to side errors turn in the displayed weight to Og Move the mass to the front back left and right edges of the Pan Note the displayed values opposite directions Correct any errors by turning Corner load Adjusting screws as shown in Figures 4 3 and 4 4 Use a nut driver Adjust as shown until the Figure 4 3 Off Center Load Adjustments on tolerance is 5 counts Pioneer Precision Balance Use small adjustments no more than turn at time Repeat Off Center Load Test Turn the balance OFF Remove the Platform Rete Re assemble the balance ne i N Adjustment See Section 3 3 11 BZ Screw Holes Turn Auto Zero back to On in Menu Setup Figure 4 4 Off Center Load Adjustment screw holes on Pre
28. 8 Remove the aluminum sleeves See Figure 3 130 9 Note the position of the Up Down Stop Screw Turn the Up Down Stop Screw so the Ratio Beam can be removed See Figure 3 131 Aluminum Sleeves u Figure 3 131 Up Down Stop Screw 10 Remove the centering pins See Figure 3 132 11 Carefully lift out the Ratio Beam See Figures 3 135 and 3 136 Figure 3 136 Ratio Beam Removed Figure 3 135 Removing the Ratio Beam 12 Remove the Aluminum Sleeves See Figure 3 137 This completes the disassembly Figure 3 137 Removing the Aluminum Sleeves CHAPTER 3 MAINTENANCE PROCEDURES 3 3 32 Installing the Ratio Beam on Block Style Load Cells 1 If anew Ratio Beam is being installed remove the existing weights from the old Ratio Beam and install them on the replacement Ratio Beam See Figure 3 138 Note Some Load Cells require one Ratio Beam weight some require two and some A Ratio Beam Weights do not require Ratio Beam weights Figure 3 138 Ratio Beam Weight Removal 2 Examine the Load Cell slotted areas to be sure all areas are clean and free of debris Hold the Load Cell up to the light to see into the slotted areas If dust or dirt appears in any slotted area use pressurized clean air normally used for cameras and gently blow out any dirt Use extreme care Critical area is shown in Figure 3 139 CAUTION A N DO NOT USE COMPRESSED OR SHOP AIR AS CONTAMINANTS AND MOISTUR
29. AN INCAL BALANCE HOUSING amp PARTS TABLE 5 3 PRECISION SQUARE PAN INCAL BALANCE HOUSING amp PARTS 0 E E 5 1 Liquid Crystal Display LCD Power Adapter For details on Load Cell and InCal Mechanism parts see Section 5 6 CHAPTER 5 PARTSLISTS amp DIAGRAMS 5 4 PRECISION DRAFT SHIELD BALANCE HOUSING amp PARTS u E oO o D E v gt an Kan ep i Q C i O Cc ae m P amp 2 2 O D oO Figure 5 4 Precision Draft Shield Balance Housing amp Parts CHAPTER 5 PARTS LISTS amp DIAGRAMS 5 4 PRECISION DRAFT SHIELD BALANCE HOUSING amp PARTS TABLE 5 4 PRECISION DRAFT SHIELD BALANCE HOUSING amp PARTS Load Cell 5a Traditional MFR 5b Block Style Load Cell Cover Draft Shield Glass 4 sides Main Printed Circuit Board For details on Load Cell and InCal Mechanism parts see Section 5 6 2 3 4 5 7 10 11 12 13 14 15 CHAPTER 5 PARTSLISTS amp DIAGRAMS ANALYTICAL BALANCE HOUSING amp PARTS 9 9 Analytical Balance Housing amp Parts 5 Analytical Balance Housing amp Parts Figure 5 CHAPTER 5 PARTS LISTS amp DIAGRAMS 5 5 ANALYTICAL BALANCE HOUSING amp PARTS TABLE 5 5 ANALYTICAL BALANCE HOUSING amp PARTS a a a EEE e e eee 5a Traditional MFR 5b Block Style 6 TI rt she asien O Se feve
30. Data output by the balance is always terminated with CRLF On the rear of the balance the 9 pin female subminiature D connector COM 1 is provided for interfacing to other devices The pin connections are shown in the illustration below TABLE 1 9 COM 1 INTERFACE PIN CONNECTIONS COM 1 Pin Connections 1 Remote Tare Zero Tare J1 l y 2 TxD 3 RxD Print J2 4 Not used 5 Ground 6 Not used 7 CTS 8 RTS 9 Remote Print Figure 1 5 COM 1 Connector External PRINT and or ZERO TARE switches may be installed as shown in the diagram Use only momentary contact switches To enable External PRINT and or ZERO TARE functions join the solder points for Tare J1 and Print J2 on the Main PCB 1 Locate solder points J1 and J2 on the Main PCB adjacent to the RS232 input jack 2 Using a low wattage soldering iron apply a small amount of solder to Join two points at J1 to enable Tare Join two points at J2 to enable Print Join the points by filling the gap Figure 1 6 Soldering points J1 and J2 Pioneer Balances Service Manual 1 9 CHAPTER 1 GETTING STARTED 1 7 RS232 Commands Commands listed in the following table will be acknowledged by the balance The balance will return ES for invalid commands TABLE 1 10 RS232 COMMAND TABLE Command Funo SSS o IP Immediate print the displayed weight stable or unstable Po Print and displayed weight stabl
31. E ARE PRESENT WHICH MAY DAMAGE THE LOAD CELL Critical Area 3 Check and clean the Magnet area To clean it use a small wooden stick with double sided tape to remove any debris See Figure 3 140 A N Note Do not remove the three screws under the magnet that surround the Temperature Sensor See Figure 3 116 page 3 43 Figure 3 140 Magnet Area CHAPTER 3 MAINTENANCE PROCEDURES 3 3 32 Installing the Ratio Beam on Block Style Load Cells 4 Re install the four Aluminum Sleeves for the Ratio Beam and four for the InCal Weight Arm See Figure 3 142 5 Inspect the slotted area on the Ratio Beam Clean it if necessary See Figure 3 141 EB Weight Arm Sleeves ZA Ratio Beam Sleeves Slotted Area Figure 3 141 Ratio Beam Vane Slotted Area larger than the four Weight Arm sleeves 6 Carefully place the Ratio Beam into position on the Load Cell Do not install the screws yet See Figures 3 143 and 3 144 Figure 3 143 Replacing the Ratio Beam Figure 3 144 Positioning the Ratio Beam over the magnet right 7 Insert a Centering Pin to hold the Ratio Beam in position as shown in Figure 3 145 A N The Centering Pin also helps to avoid stressing the internal flexures Ifthe internal flexures are stressed in the process of reassembly the Load Cell may be ruined and would then need to be replaced Figure 3 145 Centering Pin goes into first hole after upward bend in Ratio Beam
32. ELL amp PARTS INCLUDING INCAL TABLE 5 7 ANALYTICAL LOAD CELL amp PARTS INCLUDING INCAL Position Sensor Board PSB 6 Bottom Flexure Arm Assembly CHAPTER 5 PARTSLISTS amp DIAGRAMS 5 8 BLOCK STYLE INCAL LOAD CELL amp PARTS Pioneer Block Style Load Cell with InCal Figure 5 8 Block Style Incal Load Cell amp Parts CHAPTER 5 PARTS LISTS amp DIAGRAMS 5 8 BLOCK STYLE INCAL LOAD CELL amp PARTS TABLE 5 8 BLOCK STYLE INCAL LOAD CELL amp PARTS Load Cell PCB InCal Mechanism Assembly InCal Motor CHAPTER 5 PARTSLISTS amp DIAGRAMS APPENDIX A STANDARD CALIBRATION APPENDIX A STANDARD CALIBRATION A 1 CALIBRATION There are two types of standard calibration for Pioneer balances Span and Linearity Span calibration sets the balance s weighing range within pre set limits for zero and a weight value at or near the balance s capacity Linearity calibration minimizes deviation between actual and displayed weights within the balance s weighing range Three weight values are used zero a weight value in the middle of the balance s weighing range and a weight value at or near the balance s specified capacity A 1 1 Calibration Masses Before beginning calibration ensure that masses are available If you begin calibration and realize calibration masses are not available exit the menu The balance will retain previously stored calibration data See Table 4
33. ENANCE PROCEDURES 3 3 25 InCal Mechanism Installation 1 Rotate the InCal Motor shaft until the Weight is in the top position 2 Slide the new InCal Mechanism into position Fasten it with the three screws previously removed but do not fully tighten them yet 3 Position the InCal Mechanism so the spacing between the InCal Weight and the InCal Weight Arms is even on both sides See Figure 3 105 F aahi HEE i Equal Spacing Figure 3 105 InCal Mechanism Alignment Figure 3 106 Centering InCal Weight 4 Make sure the InCal Weight is lined up properly on the InCal Weight Arm It must be centered in the slots of the Weight Arm See Figure 3 106 When the Weight Mechanism is properly aligned tighten the three screws and re check alignment 5 Testthe InCal Mechanism with software See Section 3 3 21 CHAPTER 3 MAINTENANCE PROCEDURES 3 3 26 Position Sensor Assembly Removal Installation on Block Style Load Cell Position Sensor Removal 1 Remove the three screws of the Position Sensor Assembly 2 Raise the Position Sensor Assembly which is held by the magnetic field 3 Ifthe Position Sensor Assembly has to be changed unsolder the Flexible Ribbon Cable See Figure 3 107 ti EEWOBER EEIBEDELER a Unsolder 6 Contacts 3 Screws Figure 3 107 Removing Position Sensor Position Sensor Installation 1 Mount the Position Sensor Assembly Align it centrally on the Ratio Beam Pin and fasten it with the thr
34. If so the balance passes the Precision Test CHAPTER 4 TESTING 4 4 1 Precision Test Precision and Analytical Balances 5 If the deviation for any set of readings using the same mass placed on the center of the Pan is greater than the tolerance listed in Table 4 1 or 4 2 the balance does not meet the precision specification Inspect and correct the following areas 5 1 Check for mechanical obstructions Any foreign object touching any part of the moving assemblies will cause a balance to fail the Precision Test Inspect and correct as necessary 5 2 An error in the Off Center Load Adjustment can affect the results of the Precision Test Inspect and correct if necessary See the next section 4 4 2 Off Center Load Test The Off Center Load Test is used to determine whether displayed weight values are affected by moving the sample to different areas of the Pan See Figure 4 2 m DD 9 Mass Locations Figure 4 2 Mass Placement Locations for Off Center Load Test Place a mass weighing half of the balance s capacity in the center of the Pan Press the On Off button to return the reading to zero Move the mass halfway to the rear ofthe Pan and note the reading Move the mass halfway between the center and the left edge of the Pan and note the reading Repeat this test for the right and front edges and note the readings Note any differences in the displayed weight reading at all positions See Tables 4 2 and 4
35. Key Perform Off Center Load Adjustments See Chapter 4 Test the balance See Chapter 4 CHAPTER 3 MAINTENANCE PROCEDURES 3 3 19 Block Style Load Cell Disassembly amp Replacement Typical Block Style Load Cells with InCal Mechanisms installed are shown in Figure 3 97 The Load Cell illustration may vary from actual Load Cells Major components are shown InCal Weight InCal Motor Cable Connector Aluminum Sleeves Ratio Beam BIEN ele Y Base Plate InCal Mechanism Up Down Stop Screw 1InCal Weight Arm Load Cell PCB InCal Weight Position Sensor Assembly a InCal Motor Shield it i E AUT CHUR i 2 4 InCal Motor Ratio Beam Figure 3 97 Block Style Load Cells Precision above and Analytical below Block style Load Cells are repairable However if serious damage has occurred it may be necessary to replace the Load Cell Load Cell Kits are available for replacement purposes for all Block Style model balances Each kit is assembled and consists of metal base plate a Load Cell the InCal Weight Assembly mounted to the base plate and a package of labels Check the label on the balance and verify the capacity and model before ordering a new Load Cell kit Note Analytical and Precision Block Style Load Cells are different but the service procedures are the same CHAPTER 3 MAINTENANCE PROCEDURES 3 3 20 Block Style Load Cell Removal amp Replacement with Load Cell kit Use the following procedure to r
36. ON To select menus menu items and settings press Yes or No Solid arrows point to content displayed when Yes is pressed dashed lines when No is pressed CHANGE SETTINGS To select the displayed setting press Yes To move to the next setting press No EXIT MENU When END appears press Yes to exit the menu function or No to return to the Cal menu Note Press and hold No at any time to exit quickly Pioneer Balances Service Manual 1 7 CHAPTER 1 GETTING STARTED 1 5 7 The Load Cell Figure 1 4 illustrates a typical Magnetic Force Restoration MFR Load Cell The force of a weight placed on the Weighing Pan moves the Hanger which is guided by the Upper and Lower Flexure Arms The Load Flexure transfers the force vertically to the Ratio Beam The Ratio Beam Flexures form a pivot for the Ratio Beam When the Ratio Beam is moved the Force Coils mounted on the Ratio Beam are moved The Force Coils are located in the magnetic field created by the Permanent Magnets The magnetic forces are affected by temperature A Temperature Sensor is attached near the magnets to measure the temperature and allow the electronics to compensate for the changes in temperature Operation A mass placed on the Pan applies a downward force to the Load Flexure by means of the Hanger The Load Flexure moves one end of the Ratio Beam which pivots moving the Force Coil up into the air gap of the Magnet The Force Coils are located in the field of the Pe
37. Removal Replacement Adjustment Analytical When the Position Sensor PC Board is defective and requires replacement proceed as follows 1 Open the balance and remove the Thermistor wires Load Cell are soldered on 3 wire Ribbon Cable Inset Screws the bottom 2 Un solder the thermistor wires and ribbon cable See Figure 3 75 3 Remove the two inset screws holding the Position Sensor N Board in place EG AA 4 Remove the Position Sensor Board and install the replacement Insert the screws previously removed Tighten the screws finger tight to allow adjustment in Step 9 Figure 3 75 Position Sensor Board Analytical Re solder the wires See Figure 3 75 Place the Load Cell in position and insert the screws finger tight to facilitate Step 9 Connect the cable from the Main PCB to the Position Sensor Board Sa es p Operate the balance with the Weighing Pan in its normal position but with the Top Housing off Power on using the middle button on the PCB NOTE The Position Sensor Board contains an Optical Sensor which must be positioned in the Ratio Beam s center of travel for the balance to function properly 9 Adjust the vertical position of the Position Sensor Board if it is too high or too low the display indicates Error 8 X See Figure 3 76 Move the board until the display indicates other than 8 X 10 Tighten the screws on the Position Sensor Board See Figure 3 76 11
38. Service Mena B 1 BA RAND N er EI RR B 1 B3 Service Span Galibration a nee ae a a B 2 B 4 Service Linear CaliDration c ccccccccccccceccceccceccccceucecececececucecuuauacauauausenececssnstananas B 3 TABLE OF CONTENTS Page No APPENDIX C SOFTWARE SERVICE TOOL INSTRUCTIONS Gt Restore EEPROM Data ee C 2 SZ Heplace Oa Geller een C 3 C 3 Install new Main Printed Circuit Board 0s2220000222ssennnnnesnennennnnnnnnnnnn nennen C 4 C 4 Update Software in the Balance cnisia e a C 5 9 9 MDAC OS We An ea Be ee Eee C 6 C 5 1 Incal Weight Mechanism Testing cccccseeccceeseceeeseeeeeeseeeeeeeseeeeeeesseeeeeesaaeeess 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 amp CM cccccsecceeeseeeeeeeeeeeeeeens 1 3 1 3 Specitications Carat Models anna Er 1 3 1 4 Specifications Gold Models External Calibration 000222200222en een 1 4 1 5 Specifications Gold Models Internal Calibration 022220022220e 222 1 4 1 6 Admissible Ambient Conditions 1 5 1 7 F netuons of Display Control u a 1 5 1 8 IS DIAY MGIC ALORS een 1 6 1 9 COM 1 iIMteriace Pin E nneelonsan ae 1 9 1 10 RS232 Command Table Arsen ea eier 1 10 2 1 Diagnosi Gilden een el ienseae 2 2 2 2 Enor OC CS een 2 4 4 1 Vest MaSSeS Required ac aa
39. Symbols for weighing modes include g Grams kg Kilograms mg Milligrams ct Carats N Newtons Ib Pounds oz Ounces oz t Ounces troy GN Grain dwt Pennyweight mo Mommes m Mesghal t Taels Taels are available in three types Hong Kong Singapore and Taiwan cl Tical PCS Parts counting 1 6 Pioneer Balances Service Manual CHAPTER 1 GETTING STARTED 1 5 3 Power ON Press gt O T lt All segments will appear briefly followed by a software revision number when plugged in first time or after a power interruption and then 0 00g Allow one hour warm up time The balance should be calibrated before use 1 5 4 Power OFF To turn the balance OFF press and hold gt O T lt until the display indicates OFF then release 1 5 5 Menu Setup Programmable features of the Pioneer balances are contained in menus which are accessed through the Display Panel s control switches See the Instruction Manual for a full description of the menus and how to access them 1 5 6 Menu Structure a m re inca AZSI gt COUN TSTA BAUD APWOPT MILLIGRAM cA oe LINEAR PARITY HAND SH END R22 EEE nal models onh Alot available in InCal models Figure 1 3 Pioneer Menu Structure ENTER MENU When the balance is on press and hold Unit Menu until mMENU appears Release the button and the Calibrate CAL menu will display MENU NAVIGATI
40. TE A N Do not attempt these adjustments unless the balance is free from drafts The balance is very sensitive and adjustments will be affected Adjust the Block Style Load Cell by removing material from the locations indicated in Figure 4 7 Use a few strokes with a round needle file exerting slight pressure Warning Do not file at the edge at the flexible bearing positions On completion of the adjustments clean the filing sites by removing the grindings with adhesive tape do not blow the grindings away If test weight File in position s 1 Set Auto Zero to Off in Menu is unbalanced marked Setup g CES i 2 Open the balance See Section 3 1 Be 3 Reinstall the Pan 4 Plug the power cord into the balance and turn it on 5 Place a mass that weighs the balance s full capacity on the center of the Pan l i l 4 m ES HB A Figure 4 7 Using a Needle File to adjust Off 6 Press O T the center button to Center Load on Block Style Load Cells tare the balance and return the displayed weight to 0g Move the mass to the front back left and right edges of the Pan Note the displayed values 7 Correct any error by filing at one or two of the marked positions See Figure 4 7 8 Adjust as shown until the tolerance is 5 counts 9 Repeat Off Center Load Test 10 Turn the balance OFF 11 Remove the Platform and re assemble the balance
41. Test Equipment 99 Washington Street Depot Melrose MA 02176 Phone 781 665 1400 1 800 517 8431 Toll Free 1 800 517 8431 2 OHAUS SERVICE MANUAL Pioneer Balances 2 OHAU SERVICE MANUAL Pioneer Balances The information contained in this manual is believed to be accurate at the time of publication but Ohaus Corporation assumes no liability arising from the use or misuse of this material Reproduction of this material is strictly prohibited Material in this manual is subject to change Copyright 2008 Ohaus Corporation all rights reserved TM Registered trademark of Ohaus Corporation TABLE OF CONTENTS Page No CHAPTER 1 GETTING STARTED I SINIKOGLICH Omas res ee es E ee 1 1 12 SEI FAC MCS etek sera tienen een ee ee euere 1 1 1 3 Tools and Test Equipment Required cccccsscccseeecseeeeceseeceececceeeceueeeeeeessasensases 1 2 EST Specal 1008 rss ee ea 1 2 1 3 2 Standard Tools and Test Equipment 002224200022020nennnnnnennennnne nennen 1 2 1 4 SS DCCHIC AU ons nee ee 1 2 1 5 Balance Operaio nonan area erh 1 5 1 5 1 OVenMiew or the Gontr lsaurtuneiiuzeen ee ae liege 1 5 1 5 2 Overview of the Display Indicators us044444440B40nnn nn nnnn ee nnnnnnennnnnn ne nennnennnn 1 6 1 9232 POWER OT ea este ee ee rer 1 7 1 54 POWEr ON Gr ee 1 7 1 5 5 Menl Sellp amssteee nn a ee 1 7 TOG Menu SIrUCl re rr naar 1 7 1 97 APELO TO Oller en ee ee ee 1 8 16 Co
42. all the Hanger insert two screws loosely Distance shown by arrows should be 8mm Insert shims on each side and tighten screws See Figures 3 86 and 3 87 Figure 3 86 Screws from Bottom Mounting Figure 3 87 Insert shims between the Hanger Plate inserted finger tight into the Hanger and the Load Cell on both sides j EN rm j hd 7 Air v Figure 3 88 Bottom Flexure Arm Figure 3 89 Top Flexure Arm 14 Install the Bottom Flexure Arm screw side down Each screw has two washers a silver colored one near the Flexure a black one near the screw See Figure 3 88 15 Install the Top Flexure Arm screw side down See Figure 3 89 16 Install the Vertical Flexure bottom screw last Figure 90 Vertical Flexure Note the order of parts as shown in Figure 3 91 Top Bushing DEN Lock Plate Bottom Screw Elongated hole on bottom Figure 3 91 Vertical Flexure and screws Lock Plate washers and bushings Note the different sized screws and bushings for top and bottom Also note the elongated hole on the bottom side of the Vertical Flexure CHAPTER 3 MAINTENANCE PROCEDURES 3 3 18 Reassembling Analytical Load Cells 17 Install the top bracket See Figures 3 92 and 3 93 ty gt op Bracket with Top Bracket InCal Weight Arms Figure 3 92 Analytical InCal Load Cell Figure 3 93 Analytical balance Load Cell with Top Bracket visible with Top Bracket visible 18 Remove the screws and s
43. ard PCB To update the software in the balance For diagnostics Install the software on a Personal Computer running Microsoft Windows NT 4 0 or later or Microsoft Windows 98 or later Insert the CD and run Setup exe After installation run the program Service Tool The program has 5 tabs across the top of the screen Click on the tab for the function you wish to perform If the default settings for communication have been changed click on settings and change the settings in the software to match Fort Baudrate Data Parity stop bits Flow control Detaults Cancel Lik Figure C 1 Com Port Configuration Menu APPENDIX C SOFTWARE SERVICE TOOL INSTRUCTIONS C 1 To Restore the EEPROM data 1 Record the following information from the balance to be repaired 1 1 Serial Number from the label on the back of the balance 1 2 Model Number from the label on the back of the balance 1 3 IDNR Number just above the label on the back of the balance Contact Ohaus Corporation in Pine Brook NJ and request the data file to download Provide the information recorded above After receiving the data file from Ohaus continue with the following steps Connect the balance to the PC and start the Pioneer Software Service Tool Click the tab labeled Restore EEPROM Pioneer Service Tool 1 00 I JS x File Settings Restore EEPROM Replace Loadcell Replace PCE Download Software S N IDNR Ima
44. bilize the Hanger Dont touch 6 Remove the two screws and washers that secure the Top Bracket and lift it off See Figure 3 60 A N NOTE Do not touch the two rear most screws with nuts on top These are adjustment screws Figure 3 60 Analytical balance Load Cell with Top Bracket visible 7 Remove the Vertical Flexure which is located in the center of the Hanger Loosen the two screws that secure the Vertical Flexure to the Hanger Carefully remove the Lock Plate washers and bushings keeping track of their order for later reassembly as illustrated in Figure 3 61 Note Be sure to lay the Flexure on a flat surface to avoid bending it CHAPTER 3 MAINTENANCE PROCEDURES 3 3 16 Disassembling Analytical Load Cells Top Bushing IDSeeN Lock Plate Bottom Screw Elongated hole on bottom Figure 3 61 Vertical Flexure and screws Lock Plate washers and bushings removed from center of Hanger Note the different sized screws and bushings for top and bottom Also note the elongated hole on the bottom side of the Vertical Flexure 8 Carefully loosen and remove the four screws that secure the Top Flexure Arm to the Load Cell and remove the Top Flexure Arm See Figure 3 62 Place the Flexure Arm on a flat surface Note that the Flexure screws on the Analytical balances have two washers each a thicker silver colored one on the bottom and a smaller black one on top Figure 3 62 Top Flexure Arm Analyti
45. bling Analytical Load Cells NOTE Use extreme caution in moving the Contact Board to avoid stressing or breaking the A fine wires underneath it If one of these wires is broken it must be replaced 20 Remove the screw in the Contact Board that had the 3 wire Ribbon Cable soldered to it Move the Board with great care to protect the extremely delicate fine wires connected to it from underneath See Figure 3 72 21 Use a smaller screw to temporarily fasten the Contact Board to the screw hole on the top of the Ratio Beam as shown in Figure 3 73 Figure 3 73 Use a small screw to fasten the Contact Board to the Ratio Beam Screw hole to fasten Contact Board to Ratio Beam Figure 3 72 A screw connects the Contact Board to the Load Cell 22 Remove the Sideways Motion Stop Plate on the top of the Load Cell which stabilizes the Ratio Beam If necessary turn the black Up Down Stop Screw to allow the Ratio Beam to clear See Figure 3 74 23 Remove the Service Fixture and gently lift out the Ratio Beam Up down Stop Screw Screws holding Sideways Motion Figure 3 74 Two screws hold the Sideways Stop Plate Motion Stop Plate on top of the Load Cell The black Up Down Stop screw holds the Ratio Beam in place The Load Cell is now completely disassembled To reassemble the Load Cell see Section 3 3 17 Reassembling Analytical Load Cells CHAPTER 3 MAINTENANCE PROCEDURES 3 3 17 Position Sensor PC Board
46. cal Figure 3 63 Bottom Flexure Arm Analytical 9 Turn the Load Cell over and remove the four screws that secure the Bottom Flexure Arm to the Load Cell and remove the Bottom Flexure Arm See Figure 3 63 Place it on a flat surface NOTE A When handling the Flexure Arms be careful not to bend the Flexures 10 Carefully examine each Flexure to see if it is bent If uncertain place the Flexure on a clean flat surface and check that both sides rest evenly on the surface If a Flexure is bent even slightly it must be replaced for the balance to operate properly CHAPTER 3 MAINTENANCE PROCEDURES 3 3 16 Disassembling Analytical Load Cells 11 Remove the Hanger from the Load Cell by removing the two screws inserted earlier See Figure 3 64 Ratio Beam Flexures Figure 3 64 Hanger with two Screws Figure 3 65 Service Fixture attached to the front of Load Cell after removing Hanger 12 Install the Service Fixture using the finger screws provided in order to stabilize the moving parts See Figure 3 65 13 Remove the Ratio Beam Flexures a clean flat surface and check that both sides rest evenly on the surface If a Flexure N 14 Carefully examine each Flexure to see if it is bent If uncertain place the Flexure on is bent even slightly it must be replaced for the balance to operate properly 15 Remove the two screws that secure the Vane as shown in Figure 3 66 Then lift the Vane out and set it aside
47. cision models CHAPTER 4 TESTING 4 4 4 Off Center Load Adjustment for Analytical Models A 10 11 12 13 14 NOTE Do not attempt these adjustments unless the balance is free from drafts The balance is very sensitive and adjustments will be affected Set Auto Zero to Off in Menu Setup Open the balance See Section 3 1 Reinstall the Pan Plug the power cord into the balance and turn it on Place a mass that weighs the balance s full capacity on the center of the Pan Turn in direction shown by arrows For errors front to back turn both adjustments the same Press O T the center button direction For side to side errors turn in to tare the balance and return opposite directions the displayed weight to Og Move the mass to the front back left and right edges of the Pan Note the displayed values Correct any errors by turning Corner load Adjusting screws as shown in Figures 4 5 and 4 6 Use a 6mm nut driver Adjust as shown until the Figure 4 5 Off Center Load Adjustments on tolerance is 5 counts Pioneer Analytical Balance Use small adjustments no more than 1 4 turn at time Repeat the Off Center Load Test Turn the balance OFF Be Me Remove the Platform Re assemble the balance See Section 3 3 17 Turn Auto Zero back to On in Menu Setup holes on Analytical models CHAPTER 4 TESTING 4 4 5 Off Center Load Adjustment for Block Style Models NO
48. djust position of Sensor Board until Err8 X does not appear uueesnseneeeenennen 3 13 POSITION Sensor BOI is ai ae ed 3 14 Installing Ratio Beam clearing the Up down Stop Screw ccccseeeeeeeeeeeeeees 3 15 Precision Load Cell 150g to 310g top with Service Fixture attached 3 15 Service Fixture for 510g to 4100g Precision Load Cell attached to Hanger 3 15 Sideways MOLION SIO Pl ale ensnei ee uie 3 16 Two screws secure Magnet alla ern ee ia iaaetadtetaaitncals stadmetubmewaice 3 16 Contact BO AIG can nee 3 16 Solder points on Position Sensor Board uussssssennnnnnnnnnnnennnnnnnnnnn nenn 3 16 Precision Load Cell OB aussen ea ee en 3 17 Precision Load Cell Bottom 3 17 Ratio Beam Flexures and Vertical FIOXUre ce ccccceccceeeeeeeceeceeeeseeeeaeesaeeeees 3 17 Insert the 3 screws to secure Precision Load Cell in Bottom Housing 3 17 When Position Sensor Board shows normal weight tighten its screws 3 18 Analytical Balance with InCal Me Chanism cccceccsseeeeeeeeeeeeeeeeeeeeeeeeeeeeenas 3 19 InCal Weight Covers removed ccccccsseeeeececeesseeeeeseauseeeeceeeaeseeeeesesaeeeeeensanses 3 19 Bottom Housing with Load Cell Weight Arms and Weights removed 3 20 InCal Motor removed from its assembly 2u0s220000enennnenennnennnnnen nennen nenne nennen 3 20 InCal Motor Cam in correct position for reassembly
49. e or unstable p AS xP Interval Print x Print Interval 1 3600 seconds OP ends Interval Print Print version name software revision and LFT ON if LFT is set on Set PC reference weight x in grams Must have been a APW stored Print PC reference weight Sent reference weight x in grams Must have reference weight stored Print percent reference weight Stop zero the old Adventurer print format begin to use the default print format Stop using the default print format begin to use the old Adventurer print format zero Stable off S Stable on default ORL Stops the scale from sending OK in response to instruction non print commands Returns scale to default mode of sending OK 1 10 Pioneer Balances Service Manual CHAPTER 2 DIAGNOSTIC GUIDE 2 1 TROUBLESHOOTING This section of the manual provides guidelines for evaluating the condition and performance of a balance and a standard troubleshooting methodology to follow Follow all directions step by step Make certain that the work area is clean Handle balance components with care Use an appropriate Electro Static Device 2 1 1 General Procedures for Troubleshooting 1 Do the most obvious user level remedies 2 Perform Ramp check and Service Calibration 3 Check that internal parts are clean and free of debris 4 Inspect the motion of the Ratio Beam it should move up and down freely If not determine if the cause is mechanical b
50. ee screws See Figure 3 107 Note The flange of the Position Sensor Assembly is pre bent to ensure its precise positioning after screwing it on Do not attempt to bend it straight Ratio Beam Pin Sensor Assembly Hole Figure 3 108 Ratio Beam Pin Alignment 2 Solder the Flexible Ribbon Cable to the six contacts shown in Figure 3 108 3 Adjust the Up Down Stop following procedures in Section 3 3 31 CHAPTER 3 MAINTENANCE PROCEDURES 3 3 27 Removing the Block Style Load Cell from the Base Plate This procedure is necessary before proceeding with other repairs to the Load Cell Base Plate Removal 1 Remove the Weigh Below Hook and Screw See Figure 3 109 Mounting Screws Weigh Below Hook amp Screw Figure 3 109 Base Plate Removal 2 Hold the Block Style Load Cell and remove the two Load Cell Mounting Screws See Figure 3 109 Note At this point other repairs may be made to the Load Cell CHAPTER 3 MAINTENANCE PROCEDURES 3 3 28 Installing the Block Style Load Cell on the Base Plate Block Style Load Cell Surfaces Mounting Screws Me a Weigh Below Hook amp Screw Figure 3 110 Load Cell Mounting Components Base Plate Installation 1 Make sure the mating surfaces on the Base plate and the Load Cell are clean See Figure 3 110 2 Position the Load Cell on the base and install the two mounting screws Do not tighten them fully 3 Looking down at the top of the Load Cell align it wi
51. eeeceeeeeeeeeeseeseeeeeessaaeeeeeeeaas 3 6 Proper manner to grasp Load Cell when removing Weight Arm assemblly 3 7 Cable connects to Position Sensor BOard ccccccccsseecceceeeeceeeeeeeeeesaeeeeeesaaeeess 3 7 Access the 3 screws to release Precision balance Load Cell from top center 3 7 Service Fixture screws and washers for 150g to 310g Precision balances 3 8 Service Fixture screws and washers for 510g to 4100g Precision balances 3 8 Precision Load GEOD ee koeneseliieasnigiee 3 8 Precision toad Gell DONON zus ee 3 8 Precision Load Cell 150g to 310g top with Service Fixture attached 3 9 Service Fixture for 510g to 4100g Precision Load Cell attached to Hanger 3 9 BVM re KUN aster a at cc ee aac als Na a gad ten ein et 3 9 Position SENSOR BOG G anera een 3 10 Contact Board with ribbon cable ccccccceceececeeeeeeseseeeceeeeeesueceeseeeeeseseetsneess 3 10 Fine wires connected to the Contact Board and affixed to Ratio Beam 3 10 Contact Board taped to Ratio Beam after removal from frame 3 11 Fangen are ee ee lee nee 3 10 Two screws secure Magnet Half 2 2u00240022080022nn nenne nnnnnnnnnnn nenne nenne nennen 3 11 sideways Moti n Stop Plate asrni anna 3 11 Ratio Beam clearing stop on Up Down Stop Screw as it is lifted out 3 12 MAGNETS must De clean 3 12 Posion SCNSOF BOA icine ee ea 3 13 A
52. eeeeseeessusesseesaeessas 3 30 FOUR screws On Magnet Hals 3 30 POSItiON SENSOor Board u ee rein 3 30 3 wire cable soldered to Contact Board 2 2u00222200020200snennnennnnneennnnnenen 3 30 Install the Vanessa 3 30 Screws removed from Bottom Mounting Plate inserted into the Hanger 3 31 Insert shims between the Hanger and the Load Cell on both sides 3 31 BOOM Flex URC Arsen ee e a 3 31 TODE ilo UI SATT ee re easeee 3 31 vVerical Flexure rn e E EE 3 31 Vertical Flexure and screws Lock Plate washers and bushings removed 3 31 Analytical InCal Load Cell with Top Bracket VISIDIC cccccseeeeeesseeeeeeseeeeeeees 3 32 Analytical balance Load Cell with Top Bracket visible ccccsseeeeeeeeeeeeeees 3 32 Bottom Mounting Plate on Analytical Load Cell cc cccceccesseeeeeeeeeeeeeeeeeaees 3 32 Ribbon cable connects PSB to Main PCB ccccecccsseeeeceeeeeeeeeeeeeaeeeesaeeeessees 3 32 When Position Sensor Board shows normal weight tighten its screws 3 33 BIOCK SIYIE LH ACS ea nad natbnaieiasrauseiavaaedaaoadioeauies tamer indedextatent 3 34 Service Toolset for Block Style Load Cells PN 476000 0380 22u0222rs02200 gt 3 35 Gali MOTOR orenean enaa A e A a 3 36 InGalVolor Hemovalan areas east 3 36 MOIOL GOUpler nn een 3 36 Motor Shaft in counter clockwise POSITION u02220002200020n0e nenne nenne nenne ennnnenn
53. een ige 1 8 1 5 COM IFGORNECIOF roper reelle 1 9 1 6 Soldering POINTS Jand J2 un ne a 1 9 3 1 TOP BanekIINS UD and slides OUl ans S 3 2 3 2 Groove in side panel s base liner aligns with tab on Housing 3 2 3 3 Precision Load Gellwiih lne lunscse seen eure 3 3 3 4 Analytical Load Cell with Incal 220002204000 022 0nnneenennnnnnnnnnnnn nennen nnnnnnnnn 3 3 3 5 Precision Load Cell resse a a a 3 3 3 6 Anali cal Eoad Oe leinen A A aso ame eee 3 3 3 7 Precision Block Style Load Cell with InCal nnnaennnneennnnnnnnnnnennnenrnenenrnrrenrn reenen 3 4 FIGURE NO 3 8 3 9 3 10 3 11 3 12 3 13 3 14 3 15 3 16 3 17 3 18 3 19 3 20 3 21 3 22 3 23 3 24 3 25 3 26 3 27 3 28 3 29 3 30 3 31 3 32 3 33 3 34 3 35 3 36 3 37 3 38 3 39 3 40 3 41 3 42 3 43 3 44 3 45 3 46 3 47 3 48 3 49 3 50 3 51 3 52 3 53 3 54 3 55 3 56 3 57 TABLE OF CONTENTS TITLE Page No Analytical Block Style Load Cell with InCal u 042444444RRnn nennen nnnnnnnnnn 3 4 Precision Balance with InCal Mechanism ccccseeccesesececesecetseeceeseeeeeseneeeeanes 3 4 InCal Weight Cover removedin un e ni 3 5 Bottom Housing with Load Cell Weight Arms and Weights removed 3 5 InCal Motor removed from its HOUSING ccccceececceeeeeceeeeeeeeeeeesaueeessaeeeeseaeeesaees 3 6 Screws securing Weight Arm assembly ccccccsseeeec
54. eful not to Figure 3 10 InCal Weight Cover removed touch the top or bottom Flexure Arms If Load Cell is to be disassembled see Section 3 3 2 3 3 4 Servicing the Internal Calibration Mechanism 1 Follow the steps in Section 3 3 3 to remove InCal Weights and Load Cell 2 Remove the two screws that secure the Weight Lifter to the base See Figure 3 11 3 Take out the Weight Lifter 4 Remove the two screws that secure the InCal Motor Assembly 5 Lift out the InCal Motor Assembly Carefully free the InCal Motor s ribbon cable from the groove in the Housing Disconnect the cable s plug from the ad PCB on the front of the Di oo ui balance Figure 3 11 Bottom Housing with Load Cell Weight Arms and Weights removed Pioneer Balance Service Manual 3 5 CHAPTER 3 MAINTENANCE PROCEDURES 3 3 4 Servicing the Internal Calibration Mechanism 6 Remove the screws and washers that secure the InCal Motor Note Before reinstalling the InCal mechanism be sure all of its components are clean and free of debris If the InCal Motor or its Cam is defective it must be replaced Figure 3 12 InCal Motor removed from its assembly 3 3 5 Reassembling the Internal Calibration Mechanism 1 Insert the InCal Motor s cam in the hole of the InCal Motor Assembly Insert the four screws that hold the motor to the assembly and tighten them 2 Mount the InCal Motor Assembly in the Bottom Housing Carefully place the m
55. eplace a Block Style Load Cell using a Load Cell kit 1 Remove the Top Housing See Section 3 2 1 2 Remove the Load Cell Shield by grasping the sides and pulling upwards 3 Remove the four screws and washers that secure Load Cell to the Bottom Housing Remove the Load Cell 4 Disconnect the cable s on Install the replacement Load Cell using the four screws previously removed and connect the flexible cables 6 Replace the Load Cell Shield over the Load Cell Press it firmly into place 7 Reassemble the balance 8 Follow the instructions in Appendix C for installing the Load Cell 9 Re calibrate the balance following instructions in Appendix B Service Calibration 10 Re calibrate the balance following instructions in Appendix A Standard Calibration 11 Check the performance of the balance using tests in Chapter 4 3 3 21 Progressive Disassembly of Block Style Load Cells Use the following procedures for progressive disassembly of Block Style Load Cells When the defective part is reached replace it as described But note that the procedures are not meant to be stand alone you must complete each step The following steps require the Block Style Service Toolset See Figure 3 98 CAUTION A N Exercise extreme care not to twist or deform the Load Cell in any way Do not drop or hit the Load Cell Serious damage to the Load Cell can make it necessary to replace the Load Cell Figure 3 98 Service Toolset
56. er aoe the PCB into the tab on the Load ele alee Uitte if j iy Peay aa Cell frame See Figure 3 155 Set a e mala i Etat ein A N When screwing in first turn the self tapping Cell Board Screw in a counterclockwise direction until the first screw thread engages and then tighten it Figure 3 155 Groove on left of PCB fits tab See Figure 3 111 page 3 42 on Load Cell frame 2 Gently hold PCB in position while inserting and tightening the screw that secures it 3 Carefully position the Temperature Sensor under the Magnet so the Temperature Sensor a very fine thermister that extends from the board goes into the hole between the ener eer three screws on the bottom of Temperature the Magnet See Figure 3 156 ES Sensor hole Figure 3 156 Temperature Sensor 4 Insert the screw to secure the extends into a hole in the Magnet Temperature Sensor Board Note Do not adjust the screws around the Temperature Sensor hole It could ruin the Load Cell CHAPTER 3 MAINTENANCE PROCEDURES 3 3 33 Installing the Load Cell PCB Temperature Sensor Position Sensor Assembly 5 Place the Position Sensor on the Magnet It has a cavity allowing it to rest squarely aligned with the screw holes See Figure 3 157 The Ratio Beam pin must be centered in the hole in the back See Figure 3 158 Ratio Beam Pin centered in PSB hole Cavity under PSB clears Ratio Beam Vane Figure 3 157 Position Sensor
57. ers An Assembly to the base 7 Lift out the InCal Motor Assembly from the base Carefully free the InCal Motor s ribbon cable from the groove in the base Figure 3 50 Bottom Housing with Load Cell Weight Arms and Weights removed 8 Remove the screws and washers that secure the InCal Motor to the assembly 9 Note the position of the InCal Motor Cam as it is removed Be sure the Cam is in the same position when the mechanism is reassembled See Figure 3 52 Figure 3 51 InCal Motor removed from its assembly Figure 3 52 InCal Motor Cam in correct position for reassembly Before reinstalling the InCal mechanism be sure all of its components are clean and free of debris If the InCal Motor or its Cam is defective it must be replaced CHAPTER 3 MAINTENANCE PROCEDURES 3 3 14 Reinstalling Internal Calibration Components When reinstalling the Internal Calibration Components follow these steps 1 Insert the InCal Motor s Cam in the hole of the InCal Motor Assembly see Figure 3 51 insert the four screws that hold the motor to the frame and tighten them Mount the InCal Motor Assembly in the Bottom Housing See Figure 3 50 Before inserting the screws carefully place the motor s ribbon cable in the groove in the Housing and thread it beside the RS232 cable along the outside of the Housing Insert its plug in the PCB Insert and tighten the screws that hold the assembly to the Housing P
58. eseeeeeeaees 3 7 3 3 8 Load Cell Disassembly Precision Balances ccccccseseeceeeseeeeeeeeeeseaeeeeeees 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 ccccccccccssseeeeeeeeeeeseeeeeesaeeees 3 15 3 3 12 Removing the InCal Mechanism from InCal Analytical Balances 3 19 3 3 13 Removing Internal Calibration Weights and Components u en 3 19 3 3 14 Re Installing Internal Calibration COMPONENTS cccceeeeeeeeeeeeeeeeeeeeeesaaeeeees 3 21 3 3 15 Load Cell Removal Installation Analytical Balances 3 21 3 3 16 Disassembling Analytical Load CellS cccccccccccseeceeeseeeeeeeseeeeeeseeeeseessaeeees 3 22 3 3 17 Position Sensor PC Board Removal Replacement Adjustment Analytical 3 28 3 3 18 Reassembling Analytical Load Cells ccceccccccsseeceeeeeeeeeeseeeeeeeseeeeeessaneeees 3 29 3 3 19 Block Style Load Cell Removal amp ReplaceMent cccccsseseeeeeeeseeeeeeeeeeneeees 3 34 TABLE OF CONTENTS Page No 3 3 20 Block Style Load Cell Disassembly amp Replacement with Load Cell Kit 3 35 3 3 21 Progressive Disassembly of Block Style Load Cells cceeeceeeeeeeeeeeeeeees 3 35 3 3 22 Internal Calibration Testi
59. ference Mass and verify that the display returns to zero If it does not disregard the reading press ZERO to re zero the display and repeat the process Calculate the weight differences between the readings as shown below The maximum difference should be less than or equal to the Linearity specification for the instrument See Specification Tables Chapter 1 CHAPTER 4 TESTING 4 4 7 Linearity Test Record Readings Reading 1 Reference Weight added to zero Reading 2 Reference Weight added at 1 4 full scale capacity Reading 3 Reference Weight added at full scale capacity Reading 4 Reference Weight added at full scale capacity Calculate Differences Reading 1 Reading 1 Reading 2 2 Reading 2 Reading 2 Reading 3 2 Reading 3 Reading 3 Reading 4 2 Maximum Difference The difference in the weights of the test mass should be within the tolerance in Table 1 2 If not perform a Standard Calibration both Span and Linearity see Appendix A and repeat the test If the balance remains out of tolerance the Load Cell may need to be repaired CHAPTER 5 PARTS LISTS amp DIAGRAMS This section contains exploded views of the Pioneer series balances The exploded view drawings are designed to identify the parts which can be serviced on the balance in the field There are many Pioneer models that have the same parts There are eight diagrams and parts lists covering the full range of models as f
60. g Hanger 3 25 The Vane is secured by two screws near the rear of the Load Cell 3 25 The Vane TOMOV CG oe a eaten cet ease es ee de dear re er 3 25 Two solder points on PSB and two screw holes for removing the board 3 26 Contact Board with 3 wire ribbon cable soldered to it ccececesseeeeeeeeeeeeeeeneees 3 26 Four screws secure the Magnet Half to the Ratio Beam cccecceseeeeeeeeeeees 3 26 The Magnet Half when removed should be cleaned ccccecceeeeeeeeeeeeeeeeees 3 25 A screw connects the Contact Board to the Load Cell cccceccceessseeeeeeeeeeees 3 26 Use a smaller screw to temporarily fasten it to the Ratio Beam 3 26 The Sideways Motion Stop Plate and the black Up Down Stop screw 3 27 Position Sensor Board Analytical ccccccccccescecceseeeceeeeeceeeecesseecessegeeesaeeeeas 3 28 Adjust Position Sensor Board vertically until Err8 X does not appear 3 28 The Ratio Beam needs to clear the groove in the Up Down Stop Screw 3 29 Service Fixture is installed prior to installing Ratio Beam Flexures 3 29 Sideways Motion Stop Plate and Up Down Stop SCrew cccccseeeeeseeeeeeeeeees 3 29 Elongated holes on Ratio Beam Flexures go on the bottom cccccceseeeeeees 3 29 Installing the Magnet Hallf cccccccccscecseeeceeeceeeeceeeseeeesueeseeee
61. g Temperature Sensor CHAPTER 3 MAINTENANCE PROCEDURES 3 3 30 Removing the Load Cell PCB Temperature Sensor Position Sensor Assembly 4 Remove the ribbon cable ee gt connecting the Load Cell PCB to J 7 HR Ett ne hi i ink the Contact Board ce eae en ee GB e a A N 5 Remove the screw securing the l SN eke ER age m Load Cell PCB to the Load Cell aa Eran HT ee Fa herbed frame See Figure 3 117 Do not to stress the transparent Position Sensor cable or the wires holding the Temperature Sensor Figure 3 117 Load Cell PCB 3 3 31 Removing the Ratio Beam on Block Style Load Cells 1 Remove the Position Sensor PCB and Temperature Sensor the three as an assembly prior to removing the Ratio Beam See previous section If necessary remove the Contact Board Cover Note If Contact Board has a cover as in Figure 3 118 the cover holder remains after cover is removed See Figure 3 119 Figure 3 118 Contact Board Figure 3 119 ne Cover is removed by squeezing Board with cover holder the plastic post 2 Insert the Centering Pins from the Service Toolset in the holes provided See Figure 3 120 Figure 3 120 Centering pins Centering Pins Centering Pins installed i installed Figure 3 121 Centering Pins Installed CHAPTER 3 MAINTENANCE PROCEDURES 3 3 31 Removing the Ratio Beam on Block Style Load Cells 3 Hold the Contact Coil Board to ensure the Wires fine coil wires cannot
62. ge File Change Write Image File Figure C 2 The Software Service Tool s Restore EEProm Tab Enter the balance s Serial Number and IDNR number Enter the path to the image file or click the Change button to locate the file Click the Write Image File button The software will indicate the download progress When complete disconnect the power from the back of the balance then re connect 10 Perform Service Calibrations see Appendix B Test the balance APPENDIX C SOFTWARE SERVICE TOOL INSTRUCTIONS C 2 To Replace a Load Cell 1 2 8 9 Follow the steps in Section 3 2 to replace the defective load cell Open the packet containing labels that was supplied with the replacement Load Cell These labels each contain a model number followed by the IDNR number Carefully select the label that matches exactly the model number of the balance Put the new label on the balance Power the balance from an AC adapter Connect the balance to your computer Start the Pioneer Service Tool Software Click on the tab labeled Replace Loadcell Pioneer Service Tool 1 00 Ioj x Fie Settings Restore EEPROM Replace PCB Download Software Figure C 3 The Software Service Tool s Replace Load Cell Tab Enter the IDNR number xxx xx xx xxxx from the label on the back of the balance Click the Start button 10 The software will indicate the download progress When complete disconnect the
63. he first sub menu in the Service Menu is Ramp The ramp display shows the percentage of use of the A to D circuit The actual value is not as important as how it changes It should increase as the weight on the balance is increased The ramp display should remain constant without fluctuations To view the Ramp value press Yes A number will 7783579 appear and should be constant Place masses on Tg ig 7 the balance from minimum to maximum capacity Bee The reading will increase but should not fluctuate The example at right is with no weight on the Pan The reading will vary with other balances To exit the ramp function press No The balance advances to the Span calibration menu 1117 Press Yes to perform Span Calibration 7 7 ST See next page APPENDIX B SERVICE CALIBRATION B 3 Span Calibration Span calibration from the service menu allows you to set anew zero and maximum setting This is distinct from user level span calibration which allows a user to adjust the zero and maximum setting within the range established by the service menu span setting NOTE The balance should be perfectly level before attempting a span calibration Use the balance s leveling feet at the rear of the balance together with the leveling bubble which is just to the right of the Display Be careful not to touch the scale or the table while calibration is in progress as it will cause the process to fail Enter the Service Menu by pressi
64. hims from the Hanger 19 Install the Bottom Mounting Plate as shown Note the position of the Weigh Below Hook See Figure 3 94 Screws on Bottom Mounting Plate Figure 3 94 Bottom Mounting Plate on Analytical Load Cell 20 Position the Load Cell in the balance Housing Insert and tighten the three screws from underneath the Bottom Housing Be sure the Load Cell is squarely mounted in the Housing Connect the cable from the Main PCB to the Position Sensor Board See Figure 3 95 Cable from Main PCB to Position Sensor Board mu Ye TER Figure 3 95 Ribbon cable connects PSB to Main PCB CHAPTER 3 MAINTENANCE PROCEDURES 3 3 18 Reassembling Analytical Load Cells 21 22 23 24 29 NOTE The Position Sensor Board contains an Optical Sensor which must be positioned in the Ratio Beam s center of travel for the balance to function properly Adjust the Position Sensor Board power on the balance with the Top Housing off but the Weighing Pan in its normal position The On Off switch is the second button from the right on the main PCB Adjust the vertical position of the Position Sensor Board if it is too high or too low the display indicates Error 8 X Move it until the display indicates other than 8 X Then tighten the screws on the board See Figure 3 96 Figure 3 96 When Position Sensor Board shows Install the Load Cell Cover normal weight tighten its screws with an Allen
65. hten the screws carefully checking that the display does not show an i F IR error 8 X If it does repeat Figure 3 47 When Position Genser Board shows Step 18 normal weight tighten its screws with an Allen Key Install the Load Cell Cover Perform Off Center Load Adjustments See Chapter 4 Test the balance See Chapter 4 CHAPTER 3 MAINTENANCE PROCEDURES 3 3 12 Removing the InCal Mechanism from InCal Analytical Balances This section explains the steps for disassembly servicing and reassembling the Analytical balances with the InCal mechanism Figure 3 48 shows the balance with the Top Cover and Load Cell Cover removed Figure 3 48 Analytical Balance with InCal Mechanism 3 3 13 Removing Internal Calibration Weights and Components Follow these steps to remove the InCal Weight Covers and Weights 1 Remove the screws that hold Weight Covers on both sides of Load Cell See Figure 3 48 2 Lift off the Weight Covers and then lift out each of the Weights InCal Weights Figure 3 49 InCal Weight Covers removed CHAPTER 3 MAINTENANCE PROCEDURES 3 3 13 Removing Internal Calibration Weights and Components 3 Remove the Load Cell See Section 3 3 14 4 Remove the two screws that secure the Weight Lifter to the base See Figure 3 50 a SI be je 5 Take out the Weight Pie me Lifters gt A 6 Remove the screws that m 3 Screws holging f secure the InCal Motor W Weight Lift
66. ice Tool s Download Software Tab 4 Enter the path to the file to download or click the Change bution to locate the file 5 Click on the Start Download button 6 When prompted disconnect the power from the back of the balance then re connect 7 The software will indicate the download process When complete disconnect the power from the back of the balance then re connect 8 Perform Service Calibrations see Appendix B Test the balance APPENDIX C SOFTWARE SERVICE TOOL INSTRUCTIONS C 5 Diagnostics 1 Connect the balance to your computer 2 Start the Pioneer Software Service Tool 3 Click on the tab labeled Diagnostics Pioneer Service Tool 1 00 j lOl x File Settings Restore EEPROM Replace Loadcell Replace PCB Command String Send Print InCal eight Control Raise Lower Figure C 6 The Software Service Tool s Diagnostics Tab 4 To test communications click the Print button or enter an RS232 Command String from Table 4 6 and click the Send button 5 The scale s response will be shown in the box on the right C 5 1 Incal Weight Mechanism Testing Note This procedure is used to test that the Incal Weight s move s smoothly When the weight s is in the lowered position the display reading should be STABLE 1 Click on one of the InCal Weight Control buttons Raise or Lower 2 Observe weight displayed on the balance A fluctuating display value indicates the
67. ight Arm assembly 3 3 7 Removing the Load Cell Precision Balances without Internal Calibration 1 Open the balance as explained in Section 3 2 1 2 Carefully unplug the cable that connects the Main PCB to the Position Sensor Board See Figure 3 15 3 Remove the three screws holding the Load Cell in place recessed in the middle of the Load Cell See Figure 3 16 4 After removing the three screws carefully lift the Load Cell out of the base lt is now possible to disassemble the Load Cell for cleaning alignment or replacing parts Pioneer Balance Service Manual 3 7 v Fa ti 7 j gt x j 4 f y G d d gt D f Figure 3 15 Cable connects to Position Sensor Board a j r a PP ee EEG EREHERE L x m un en en Ge Figure 3 16 Access the 3 screws to release Precision balance Load Cell from top center CHAPTER 3 MAINTENANCE PROCEDURES 3 3 8 Load Cell Disassembly Precision Balances The following steps require the Service Fixture for the Load Cell you will be disassembling Note AN Do not attempt repairs without the correct fixture Figure 3 18 Service Fixture screws and Figure 3 17 Service Fixture screws and washers for 510g to 4100g Precision washers for 150g to 310g Precision balances balances Readability 0 01g to 0 1g Readability 0 001g PN 923345 PN 923389 1 Install the Service Fixture on the front of the
68. inding or electrical malfunction 5 Make an electrical check of the Ratio Beam measure the resistance of the coils in the Ratio Beam 6 Check the InCal Mechanism if applicable It should move up and down smoothly 7 Inspect the Load Cell components Be sure they are clean and that no Flexures are bent If they are they must be replaced 2 2 DIAGNOSTIC GUIDE Table 2 1 is a Diagnostic Guide designed to help locate the problem area quickly and easily The probable causes are listed with the most common cause first If the first remedy does not fix the problem proceed to the next remedy Before attempting to repair the balance read all chapters of this manual to be familiar with the balance components and operation 2 2 1 Diagnosis 1 Isolate and identify the symptom 2 Refer to Table 2 1 Diagnostic Guide and locate the symptom Also consult Table 2 2 Error Codes for solutions to specific Errors 3 Follow the suggested remedies in the order they appear 4 Perform the indicated checks as summarized in the Section 2 4 General Troubleshooting Procedures or see the appropriate section of the manual 5 Repair or replace the defective part of the balance NOTE lf more than one symptom is observed approach one area at a time and remember that the symptoms may be interrelated If a problem arises that is not covered in this manual contact Ohaus Corporation for further information Pioneer Balance Service Manual
69. justment for Precision Models c cccceeseeeeeseeeeeeeeeeeees 4 4 4 4 4 Off Center Load Adjustment for Analytical Models cccccsseeeeeeeseeeeeeeeeeeees 4 5 4 4 5 Off Center Load Adjustment for Block Style Models cccceeceeseeeeeeeeeeeees 4 6 AAG Rep atapility TeSt cmspa e E a DETE 4 7 AAT Linearity Testen a E E E T E 4 9 CHAPTER 5 DRAWINGS AND PARTS LISTS 5 1 Precision Top Load Balance Housing amp Internal Parts uu0244002440 Rennen 5 2 5 2 Round Pan Block Style InCal Balance Housing amp Internal Parts 5 4 5 3 Square Pan Block Style Square Pan Balance Housing amp Internal Parts 5 6 5 4 Precision Draft Shield Balance with Draft Shield Housing amp Parts 5 8 5 5 Analytical Balance Housing amp Internal Parts uu224u02240002nnn nenne nenne nenne nennen 5 10 5 6 Precision Balance Load Cell amp Parts 22u000222200nnnnnnnennnnnnennnnnnnn nennen ennennnn 5 12 5 7 Analytical Balance Load Cell amp Parts ereraa a a A 5 14 5 8 Block Style InCal Load Cell amp Parts 2000022220seennnnnneennennnee nennen nnnennnn nennen 5 26 Appendix A STANDARD CALIBRATION Pest CraliDVA OM set cease nen een A 1 Alei 2GalibrationMasses nee a een esse A 1 A2 Span cal rator nasse ee een A 1 Aco Linsarty Galibration sie A 2 Appendix B SERVICE CALIBRATION Bal Entering Ihe
70. ken the Ratio Beam must be replaced Note The fine wires are glued to Figure 3 27 Contact Board taped to Ratio a post on the Ratio Beam See Beam after removal from frame Figure 3 27 This same glue provides insulation If the wires are disconnected from the Ratio Beam the insulation may be damaged causing a short circuit If this happens the Ratio Beam must be replaced 3 10 Pioneer Balances Service Manual CHAPTER 3 MAINTENANCE PROCEDURES 3 3 8 Load Cell Disassembly Precision Balances 15 Remove the Service Fixture releasing the Hanger See Figure 3 28 Figure 3 28 Hanger 16 Remove the two screws from the Magnet Half See Figure 3 29 Pull the Magnet Half away from the Ratio Coil Pull hard to overcome magnetic force and any possible corrosion 17 Remove the screws in the Sideways Motion Stop Plate Hole and lift it off See Figure 3 30 ia must wi ww tafata te Figure 3 29 Two screws secure Magnet Half Figure 3 30 Sideways Motion Stop Plate Pioneer Balance Service Manual 3 11 CHAPTER 3 MAINTENANCE PROCEDURES 3 3 8 Load Cell Disassembly Precision Balances 18 Note the position of the opening and then turn the black Up Down Stop Screw so the Ratio Beam can clear the stop and gently lift out the Ratio Beam Figure 3 31 Ratio Beam clearing stop on Figure 3 32 Magnets must be clean Up Down Stop Screw as it is lifted out The Load Cell is now complete
71. ly disassembled To reassemble the Load Cell see Section 3 3 11 Load Cell Reassembly Precision Balances 3 12 Pioneer Balances Service Manual CHAPTER 3 MAINTENANCE PROCEDURES 3 3 9 Position Sensor Board Removal Replacement Adjustment Precision If the Position Sensor Board is defective and requires replacement proceed as follows 1 2 o E o E 10 11 Open the balance and remove the Load Cell Un solder the wires that attach to the Position Sensor Board The 3 wire Ribbon Cable is connected to the Contact Board The two white wires at the top are thermistor wires polarity is not important The two wires at the bottom right must be placed back in their original 3 wire Ribbon position See Figure 3 33 Cable Thermistor cables White Red Figure 3 33 Position Sensor Board Remove the three screws holding the Position Sensor Board in place The two on the right have washers The one on the left doesn t Remove the Position Sensor Board and install the replacement Insert all screws previously removed Tighten the screws finger tight to allow adjustment in Step 9 Re solder all wires See Figure 3 33 Place the Load Cell in position and mount it with one screw Connect the cable from the Main PCB to the Position Sensor Board Operate the balance with the Weighing Pan in its normal position but with the top cover off Power on using the middle button on the PCB NOTE The Position Sens
72. lytical Load Cell Section 3 3 6 page 3 7 Section 3 3 14 page 3 20 For Block Style Load Cells see next page Pioneer Balance Service Manual 3 3 CHAPTER 3 MAINTENANCE PROCEDURES 3 3 1 Variations in Pioneer Load Cells Figure 3 7 Precision Block Style Load Cell Figure 3 8 Analytical Block Style Load Cell with InCal Section 3 3 11 page 3 28 with InCal Section 3 3 11 page 3 28 3 3 2 Disassembly of Precision Balances with Internal Calibration Precision balances that have InCal require additional disassembly procedures See Section 3 3 2 page 3 4 This section explains the additional steps required to disassemble service and reassemble the Precision balances with InCal mechanism Figure 3 9 shows the balance with Top Cover and Load Cell Cover removed InCal Motor nn Screws in InCal ER Weight Cover Screws in InCal Weight Cover Figure 3 9 Precision Balance with InCal Mechanism 3 4 Pioneer Balances Service Manual CHAPTER 3 MAINTENANCE PROCEDURES 3 3 3 Removing Internal Calibration Weights Follow these steps to remove the InCal Weight Covers and Weights 1 Remove the screws that hold the Weight Covers on both sides of Load Cell 2 Lift off the Weight Covers and lift out each of the Weights See Figure 3 10 3 Remove the Load Cell Remove the three screws holding the Load Cell in place as shown in Figure 3 16 on page 3 7 4 Lift out the Load Cell from the base Be car
73. mples See Instruction Manual LOWrEF Reference weight is too low for Add additional samples or continue to accurate parts counting or weigh with less accurate results percent weighing Unstable weight reading Check environment area should be free of vibrations air currents or drafts and temperature should meet the balance specifications Perform Troubleshooting measures See Section 2 1 1 2 4 Pioneer Balances Service Manual CHAPTER 3 MAINTENANCE PROCEDURES 3 1 PREVENTIVE MAINTENANCE Ohaus balances are precision instruments and should be carefully handled stored in a clean dry dust free area and cleaned periodically Follow these precautionary steps When a balance has had chemicals or liquids spilled on it all exterior surfaces should be cleaned as soon as possible with warm water on a damp cloth Do not leave a mass on the balance when the balance is not in use Allow time for the balance to stabilize after moving it from an area which is at a different temperature than the area where it is to be operated Allow one hour for each 5 F or 3 C temperature change before using the balance Following temperature stabilization allow an additional hour after connecting power to the balance for the balance to stabilize 3 1 1 Preventive Maintenance Checklist The balance should be inspected and checked regularly as follows 1 Remove the Pan and Pan Support to inspect and clean the area beneath the Pan
74. n a E a 4 1 4 2 Tolerances Precision Models 22200022000200002000000nnonnnn nennen nnnnnnnnne nennen 4 2 4 3 Tolerances Analytical Models u 0222s00220200000000 000000 nenne nnnnnnnnnnne nennen 4 2 4 4 Repeatability Worksheet 2u0224002000000000nnnnn nenn nenne nnnnnnnnnn nenn nnnnnn nenn nennen 4 8 5 1 Precision Top Load Balance Housing amp Internal Parts u0224002220 02H nennen 5 3 5 2 Round Pan Block Style InCal Balance Housing amp Internal Parts 5 5 5 3 Square Pan Block Style Square Pan Balance Housing amp Internal Parts 5 7 5 4 Precision Draft Shield Balance with Draft Shield Housing amp Parts 5 9 5 5 Analytical Balance Housing amp Internal Parts u00244002440 Rennen nnnn nennen 5 11 5 6 Precision Balance Load Cell amp Parts u0 22220000222000ennnnnneennennnen nennen nennen 5 13 97 Analytical Balance Load Cell amp Parts uus2222000s222nnnnennennnnennennnennnennnennneen 5 15 5 8 Block Style InCal Load Cell amp Parts uusssncnnueensnsnnennnnnnennnnnnneonnnnnnn ernennen 5 17 LIST OF ILLUSTRATIONS FIGURE NO TITLE 1 1 Pioneer Carat and Gold Series DisplayS ccccccccecccsseeeeceeseeeeseeeeeeeseeeeseesanees 1 5 1 2 Pioneer Display INGICALONS ae seen E ETE S 1 6 1 3 Pioneer MENU STUELIrE ee aaa 1 7 1 4 EoadiGelkASSeEmb Vu
75. nents Before servicing the balance you should be familiar with the Instruction Manual which is packed with every balance 1 2 SERVICE FACILITIES To service a balance the service area should meet the following requirements e Should be temperature controlled and meet the balance specifications for temperature environmental requirements See specifications for temperature ranges of the various models e Must be free of vibrations such as fork lift trucks close by large motors etc e Must be free of air currents or drafts from air conditioning heating ducts open windows people walking by fans etc e Area must be clean and air must not contain excessive dust particles e Work surface must be stable and level e Work surface must not be exposed to direct sunlight or radiating heat sources e Use an approved Electro Static Device CHAPTER 1 GETTING STARTED 1 3 TOOLS AND TEST EQUIPMENT REQUIRED 1 3 1 Special Tools 1 Fixture P N 923345 Corp Item No 00923345 for use with 150g to 410g Load Cells 2 Fixture P N 923389 Corp Item No 00923389 for use with 510g to 4100g Load Cells 3 Fixture P N 476001 020 Corp Item No 80250050 for use with analytical load cells 4 Block Style Fixture P N 476000 030 Corp Item No 80250383 1 3 2 Standard Tools and Test Equipment Digital Voltmeter DVM Input impedance at least 10 megohms in 1 V DC position Nutdriver 6mm Hex or Allen key wrenches metric Other assorted hand to
76. ng ea 3 36 3 3 23 InCal Motor Removal amp Replacement cccceccecseeeeeceeeeeseseeeeeeeeeesaeeeeeneeeeees 3 36 3 3 24 InCal Mechanism REMOVA orsu a 3 37 3 3 25 InCal Mechanism Installation ccccccccseceeceeseeeceeeeceeeeseeeeeeseeeeseeeesseeeeess 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 nn 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 uuen 3 43 3 3 31 Installing the Ratio Beam on Block Style Load CellS ccccccseeeceeeeeeeeeeees 3 47 3 3 32 Installing the InCal Weight Arm ccccccssecesseececceeeeeceeseessaeeeeseeseeseeseessaeeeses 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 AN TOSUN indek a a 4 1 ALt Test Masses Regue d csata een 4 2 AZ Operate TEST eanne ebene 4 1 4 3 Segment Display TES iuie a a e a a a a 4 1 AA PCMOnMANGE 1 CSS neuen 4 2 4 41 Precision Festina eier 4 2 4 2 2 Ot Center Load Tesla a ine eicehelnd bie te yet eames 4 3 4 4 3 Off Center Load Ad
77. ng Mean Sum of readings 10 Delta Reading Mean Standard Deviation Square Root of sum of Delta x Delta 9 5 Add the ten readings and divide the total by 10 to find the Mean average 6 Mean Reading 1 Reading 2 Reading 3 Reading 4 Reading 5 Reading 6 Reading 7 Reading 8 Reading 9 Reading 10 10 Mean 7 Calculate the Delta for each reading and record in the work sheet Delta Reading Mean 8 Calculate the Delta x Delta for each reading and record in worksheet 9 Add the ten Delta x Delta values and divide by 9 10 Calculate the Standard Deviation by taking the square root of the result from Step 9 Standard Deviation o Note Ifthe balance does not meet specifications move it to a suitable location ensure that it is level and try again If it still does not meet specifications perform a service calibration and try again See Appendix B for Service Calibration CHAPTER 4 TESTING 4 4 7 Linearity Test This test is used to determine the linearity of the unit throughout its operating range The displayed readings are compared with the tolerances listed in the specifications for the instrument See Specifications Tables Chapter 1 Tolerance values are expressed in counts A one count change is equal to the last digit shown on the scale display The masses used to perform this test can be utility masses 10 11 12 13 14 NOTE The balance must be warmed up p
78. ng and holding IEO OT od we On Zero Off and Unit together As the balance powers Te ST LOLS up SERVICE appears followed by RAMP er _ m Press No to advance to Span Calibration SUIS S 4s 3 SPAN appears Press Yes dala ae The specified maximum mass weight flashes a lm Place the indicated weight in the center of the Pan Ot Busy flashes After a few seconds Clear Pan flashes 10711 Remove the mass from the Pan SOLO a 0 flashes as the balance calibrates a zero setting 7 When span calibration finishes Linear appears J S Press Yes to proceed to Linear Calibration r sI 1 To exit press No and then Yes to end service calibration NOTE If calibration fails ensure that the test area is free from drafts and the surface the balance rests on is level and free of vibrations Then try to calibrate again If it continues to fail there may be an internal problem To resolve internal problems follow procedures in Chapter 3 B 4 Linear Calibration Linear calibration automatically follows Span calibration To start from the Service Menu press and hold On Zero Off and Unit together As the balance powers up SERVICE appears followed by RAMP Press No twice to bypass Ramp and Span calibration When Linear appears press Yes J vs If PUSH flashes place maximum weight on the Pan Aa CAIL DAND After a few seconds Clear Pan flashes Pag J Tng S Remove the mass from the Pan 9 1 gt 0 flashes for a few seconds as
79. nnecting the R9232 nterna E assisi i a ES 1 9 77 RO232 CO man N A A AE TEA 1 10 CHAPTER 2 TROUBLESHOOTING 2 1 Troupleshooting creii Lee 2 1 2 1 1 General Procedures for Troubleshooting cccccseeeceeeseeeeeeeeeeeeeseeeeeeeeeeeeeeeeas 2 1 2 2 Diagnose Oudenaren iinieleiliellsrileilssiisira 2 1 2 2 DIAGNOSIS areas 2 1 2 3 EO OOOO eaa a ee er een 2 4 CHAPTER 3 MAINTENANCE PROCEDURES 3V Preventve Maintenance zus a ae ae 3 1 3 1 1 Preventive Maintenance Checklist 2 22000022040000Bnnnnnn nennen nnnnnnne een 3 1 32 ODEningtne Balances ese EE 3 1 3 2 1 Variations in Opening Pioneer Models cccccceeeeeeeeeeeeeeeeeeeeeeseeneeeeeneeeeeeens 3 2 3 3 Load Cell Removal and Disassembly 2u00022020000200nnnennnnnnnnnnnnnnnnn nennen nennen 3 3 33 1 Variations in Pioneer Load Cells ssisirersarsnenngnias s eA 3 3 3 3 2 Disassembly of Precision Balances with Internal Calibration 3 4 3 3 38 Removing Internal Calibration Weights cccccssssseeceseeeeeeeeeesseseeeeeseaaeeeeees 3 5 3 3 4 Servicing the Internal Calibration Mechanism cccccccseeseeeeeeseeseeeeeseaneeeeeees 3 5 3 3 5 Reassembling the Internal Calibration Mechanism ccsscceeessseeeeeeeeeeeeeees 3 6 3 3 6 Disassembly of Precision Balances with InCal Mechanism en 3 6 3 3 7 Removing the Load Cell Precision Balances ccccccccescceceseeeeseeee
80. nnnnennnennnnn nennen nnnnnnnneenn 3 49 Four Ratio Beam sleeves are larger than the four Weight Arm sleeves 3 49 Replacing ne Ralo Bean ana ee 3 49 Positioning the Ratio Beam over the Magnet ccccssecccseeeeeeeeeseeeeseeeeeseeeees 3 49 Centering Pin goes into first hole after upward bend in Ratio Bean 3 49 InCal Weight Arm before insertion ccccccseeeeeeceeeeeeeeeeeeeeeaeeeeeeeseeeeessaaeeeeees 3 50 Inserting InCal Weight Arm cccccccssseeeeecessseeeeeceeeeaeeeeeeaeeaeeeeessaaaseeeeessaaaes 3 50 Weight Arm must be lifted slightly to insert Centering Pin 3 50 Proper method for tightening nuts while holding screw head stationary 3 50 Centering PINs in Ratio BEAM ccccsssecccccccessseeeeeceeeseeeeeeseeeseeeeesesaseeeeeessanseeeees 3 51 TIGHIEHING Matlo Beam NUlsasseitiseiee Nee 3 51 UB BOWN SIOD SCIO W esen aa see 3 51 Repositioning the Contact Board and Screw uuussssessssnnnsssennnnnnnnnnnnnennnnnnnnnnnn 3 51 Load Cell PCB Temperature Sensor and Position Sensor u0 3 52 Groove on left of PCB fits tab on Load Cell frame 4ssssnnne nennen 3 52 TABLE OF CONTENTS LIST OF ILLUSTRATIONS FIGURE NO TITLE Page No 3 156 Temperature Sensor extends into a hole in the Magnet cccssseeeeeeseeeeeeees 3 52 3 157 Position Sensor on the Magnet anne 3 53 3158 Pin Centered IPOD
81. ollows Precision Balances Section 5 1 Precision Round Pan Balance Housing amp Parts Section 5 2 Precision Round Pan Balance InCal Housing amp Parts Section 5 3 Precision Square Pan Balance InCal Housing amp Parts Section 5 4 Precision Draft Shield Balance Housing amp Parts Analytical Balances Section 5 5 Analytical Balance Housing amp Parts Load Cells section 5 6 Precision Load Cell amp Parts including InCal section 5 7 Analytical Load Cell amp Parts including InCal Section 5 8 Block Style Load Cell Assembly including InCal Precision Precision Precision Precision Round Pan RoundPaninCa SquarePaninCal Draft Shield PA512 PA512C PAJ603C PA213C PA2102 PA2102C PAJ1003C PA413C PA4102 PA4102C PAJ2003C PA4101 PA4101C PAJ812 PAJ2003 PAJ2102 PAJ3102 PAJ4102 PAJ2101 PAJ3101 PAJ4101 InCal Balances have been produced with either traditional MFR or Block Style Load Cells NOTE In all cases where a part is replaced the balance must be thoroughly checked after the replacement is made The balance MUST meet the parameters of all applicable specifications in this manual lf further technical information is needed please contact Ohaus Corporation www ohaus com 19A Chapin Road P O Box 2033 Tel 973 377 9000 Pine Brook NJ 07058 2033 USA Fax 973 593 0359 In the United States call toll free 800 526 0659 between 8 00 a m and 6 00 p m EST CHAPTER 5 PARTSLISTS amp DIAGRAMS 5 1 PRECISION
82. ols tweezers adjustable open wrenches etc Soldering iron 50 watt and solder rosin core solder not acid core ox WE ee IN Solder remover 1 4 SPECIFICATIONS Complete specifications for the Ohaus Pioneer Balances are listed in Tables 1 1 1 5 When a balance has been serviced it must meet the specifications listed in the table Before servicing the balance determine what specifications are not met TABLE 1 1 SPECIFICATIONS EXTERNAL CALIBRATION MODELS includes M Models coe pren ans mau nun em rau ru rum na ea Stabilization 3 Seconds 50 or 50or 100 or 100 or 100 or 200 or 200 or 200 or 1000 or 1000 or 20 50 100 100 100 150 200 200 1000 1000 35 in 9cm 47 in 12cm 7 1 in 18 cm 10 Ib 4 5 kg 7 3 Ib 3 3 kg CHAPTER 1 GETTING STARTED 1 4 SPECIFICATIONS TABLE 1 2 SPECIFICATIONS INCAL MODELS C amp CM paa mac mas max en me wa 6 mo vo mo mo so mm am amo mo o v in st eo o o BER a EEE TE eo om i om Tare Range To capacity by subtraction Stabilization 3 Seconds 50 or 100 or 100or 200 or 1000 or Span Cal Mass g 50 or 60 200 or 400 2000 2000 or 4000 Pan Diameter Diameter 3 5 in 9 cm 4 7 in 12 cm 7 1in 18 cm TABLE 1 3 SPECIFICATIONS CARAT MODELS ma eya pya ges pame mann aa ee mg 0 1 std dev 1 std dev Linearity 0 003 0 003 0 03 Tare Range To capacity by subtraction Stabiliza
83. or Board contains an Optical Sensor which must be positioned in the Ratio Beam s center of travel for the balance to function properly Adjust the vertical position of the Position Sensor Board if it is too high or too low the display indicates Error 8 X See Figure 3 34 Move it until the display indicates other than 8 X Tighten the screws on the Position Sensor Board See Figure 3 35 oaa see bk oo Insert and tighten the two Figure 3 34 Adjust position of Sensor Board remaining screws to secure the until Err8 X does not appear Load Cell Check again that an Error 8 X is not displayed Note A 2 5mm Allen Key can be cut to fit the space between the Housing and the Position Sensor Board Pioneer Balance Service Manual 3 13 CHAPTER 3 MAINTENANCE PROCEDURES 3 3 9 Position Sensor PC Board Removal Replacement Adjustment Precision 12 After completing the adjustment turn the balance off and remove the Pan and Pan Support Mounting Screw Mounting Screws Figure 3 35 Position Sensor Board 13 If a new Position Sensor Board has been installed see Appendix C and follow the instructions to restore the EEPROM 3 3 10 Main Printed Circuit Board PCB Replacement All Balances If the Display persistently shows Error 1 invalid checksum data or 2 overload or underload condition and normal remedies fail to solve the problem the PCB may need to be replaced 1 Disconnect the Load Cell Cable
84. osition the Weight Lifter as in Figure 3 50 insert and tighten the screws holding it to the Housing Install the Load Cell in the Housing carefully place the InCal Weights in the Weight Holders position the Weight covers above them insert and tighten the screws Test the InCal mechanism see Appendix C Section C 5 1 Incal Weight Mechanism Testing 3 3 15 Load Cell Removal Installation Analytical Balances 8 10 11 lt is now possible to disassemble the Load Cell for cleaning alignment or replacing parts Disassemble the Housing and open the balance See Section 3 2 1 Carefully unplug the cable that connects the Main PCB to the Position Sensor Board See Figure 3 53 Figure 3 53 Cable connects to the Position Sensor Board Remove the three screws holding the Load Cell in place in the middle of the Bottom Housing See Figure 3 54 Carefully lift the Load Cell out of the base To re install the Load Cell follow Steps 1 through 4 in reverse Figure 3 54 On Analytical balances the 3 screws securing Load Cell are on bottom CHAPTER 3 MAINTENANCE PROCEDURES 3 3 16 Disassembling Analytical Load Cells The following steps require the Service Fixtures for the Load Cell you will be disassembling Note AN Do not attempt repairs without the correct fixture The Service Fixture for the Analytical balances includes two shims See Figure 3 55 Figure 3 55 Service Fixture screw
85. otor s ribbon cable in the groove in the Housing and thread it beside the RS 232 cable along the outside of the Housing Insert its plug in the PCB Then insert and tighten the screws that hold the assembly to the Housing 3 Position the Weight Lifter frame as in Figure 3 11 insert and tighten the screws holding it to the Housing To reassemble Precision Load Cells see Section 3 3 11 4 After installing the Load Cell place Weights in Weight Holders and test the InCal mechanism see Appendix C Section C 5 1 Incal Weight Mechanism Testing 3 3 6 Disassembly of Precision Balances with InCal Mechanism 1 Remove the Load Cell as described in Section 3 3 3 2 Turn the Load Cell over so the Weight Arm assembly is visible See Figure 3 13 Figure 3 13 Screws securing Weight Arm assembly 3 6 Pioneer Balances Service Manual CHAPTER 3 MAINTENANCE PROCEDURES 3 3 6 Disassembly of Precision Balances with InCal Mechanism 3 Hold the top and bottom of the Hanger when removing the Weight Arm assembly as illustrated in Figure 3 14 Note Avoid touching the top and bottom Flexure arms 4 Very carefully remove the screws shown in Figure 3 13 and lift off the Weight Arm assembly while continuing to hold the Hanger 5 When reinstalling the InCal Weight Arm assembly follow Steps 1 through 5 in reverse a 2 ie p r d gt pE p 1 Figure 3 14 Proper manner to grasp Load Cell when removing We
86. ration See Appendix A 1 Enter Service mode Appendix B and perform a Span Calibration If this fails check the InCal Weight Assembly and the Load Cell Assembly Ensure that all parts are clean and properly aligned Repair the Load Cell See Chapter 3 Replace the PCB Pioneer Balances Service Manual SYMPTOM Balance will not calibrate using internal calibration but calibration motor is working Calibration Motor is not working Unable to display weight in a particular weighing Balance Unable to access a particular mode CHAPTER 2 DIAGNOSTIC GUIDE TABLE 2 1 DIAGNOSTIC GUIDE Unstable environment InCal Mechanism may be misaligned or not moving smoothly Calibration Motor may be defective Load Cell Motor Assembly jammed Main PC board is defective Weighing Balance not enabled in menu Pioneer Balance Service Manual 2 3 PROBABLE CAUSE REMEDY Move the balance to a location without draft or vibration Level the balance using leveling feet on rear of chassis together with leveling bubble Use software tool to test mechanism See Section C 5 1 Appendix C To correct problem see Section 3 3 Remove the Calibration Motor check the Calibration Motor with software tool See Section C 5 1 Appendix C replace if defective lf motor is OK continue with testing entire assembly With motor removed move the InCal Mechanism by hand If binding is found replace
87. rior to performing these tests and must pass the Precision Off Center Load Test and Repeatability Tests and be calibrated before the Linearity Test may be performed The Reference Mass should be approximately 1 8 of the full capacity of the balance USE THE SAME REFERENCE MASS THROUGHOUT THE LINEARITY TEST Press ZERO to zero the display Place the Reference Mass in the center of the pan and record the exact value all decimal places displayed Remove the Reference Mass and verify that the display returns to zero If it does not disregard the reading press ZERO to re zero the display and repeat the process Place a mass equal to 1 4 of the full scale Capacity on the platform and press ZERO Add the Reference Mass to the center of the platform and record the value Remove the Reference Mass and verify that the display returns to zero If it does not disregard the reading press ZERO to re zero the display and repeat the process Place a mass equal to 12 of the full scale Capacity on the platform and press ZERO Add the Reference Mass to the center of the platform and record the value Remove the Reference Mass and verify that the display returns to zero If it does not disregard the reading press ZERO to re zero the display and repeat the process Place a mass equal to 3 4 of the full scale Capacity on the platform and press ZERO Add the Reference Mass to the center of the platform and record the value Remove the Re
88. rmanent Magnets The movement of the Vane which is connected to the Ratio Beam is detected by the Position Sensor The Position Sensor contains a sender and receiver When the Vane moves the amount of light sent to the receiver also changes The change in the position of the Sensor Vane is measured and used along with the Temperature Sensor signal to adjust the current in the Force Coils The current in the Force Coils produces a magnetic field which restores the Ratio Beam to its normal position Ratio Fass reed a a a Coils j Upper Flexure Arm oi 4 lt 0p Bracket Hanger Temperature u Ratio Beam Sensor L Flexure Sensor Printed Circuit Board y lt Vertical Flexure a Bottom Flexure Arm Flexure Figure 1 4 Load Cell Assembly 1 8 Pioneer Balances Service Manual CHAPTER 1 GETTING STARTED 1 6 Connecting the RS232 Interface When the interface is connected to a computer two way communication between the computer and balance is possible using the commands outlined in the RS232 Command Table 1 10 RS232 Commands All communication is accomplished using standard ASCII format Only the characters shown in the RS232 Command Table 1 10 are acknowledged by the balance Invalid command response ES error indicates the balance has not recognized the command Commands sent to the balance must be terminated with a carriage return CR or a carriage return linefeed CRLF
89. rs 9 Draft Shield Posts rn tt Draft Shield Top 2 277777 Te O 14 Liquid Crystal Display LCD a0 Power adapter O For details on Load Cell and InCal Mechanism parts see Section 5 7 y 2 3 4 5 7 10 11 12 13 14 5 CHAPTER 5 PARTS LISTS amp DIAGRAMS PRECISION LOAD CELL amp PARTS INCLUDING INCAL 5 6 aD BB Bb InCal Weights for Precision Top Load Pioneer Precision Load Cell with InCal Parts InCal Parts Figure 5 6 Precision Load Cell amp Parts including InCal CHAPTER 5 PARTS LISTS amp DIAGRAMS 5 6 PRECISION LOAD CELL amp PARTS INCLUDING INCAL TABLE 5 6 PRECISION LOAD CELL amp PARTS INCLUDING INCAL PARTS 6 Bottom Flexure Arm Assembly po 8 Hanger o 9 LEDAssembly o 14 InCal Weights 14a InCal Weights for Balance up to 410g 14b InCal Weights for Balance over 410g CHAPTER 5 PARTS LISTS amp DIAGRAMS 5 7 ANALYTICAL LOAD CELL amp PARTS INCLUDING INCAL 0 N x oF DY 0 HD SN Y yY Q 0 0 wp ASA 0 O 0 w 0 amb 0 O w 0 Q wp 0 0 comfy o Q M Pioneer Analytical Load Cell w InCal Parts InCal Parts Figure 5 7 Analytical Load Cell amp Parts including InCal CHAPTER 5 PARTS LISTS amp DIAGRAMS 5 7 ANALYTICAL LOAD C
90. s and shims for Analytical balances 1 Remove the three screws and washers from the Mounting Plate and lift it off Set aside two of the screws to use in the next step See Figure 3 56 Loosen these screws Screws on Bottom Mounting Plate Figure 3 56 Bottom Mounting Plate and Figure 3 57 Top Mounting Plate and Flexure Flexure Arms Analytical balance s Load Cell Arms Analytical balance s Load Cell 2 Loosen the screws that secure the Flexure Arms to the Load Cell not the Hanger See Figures 3 56 and 3 57 CHAPTER 3 MAINTENANCE PROCEDURES 3 3 16 Disassembling Analytical Load Cells 3 To protect the Flexures secure the Hanger to the Load Cell with two screws and the shims supplied with the Service Fixture Use two screws that were removed from the Bottom Mounting Plate earlier Insert them finger tight in the holes of the Hanger See Figure 3 58 4 Insert the shims from the Service Kit between the Hanger and the Load Cell on the right and left ofthe Hanger See Figure 3 59 Keep the screws finger tight while inserting the shims to avoid risk of damaging the Flexures Lock Plate protecting _Vertical Flexure inserted in Hanger to secure it Figure 3 58 Screws removed from Bottom Mounting Plate inserted finger tight into the Hanger Figure 3 59 Shims are inserted between the Hanger and the Load Cell on the left and right of the Hanger 5 Tighten the two screws that Ad sag Justment screws Sta
91. t secure the Fixture to the Load Cell frame and the Ratio Beam See Figures 3 38 and 3 39 Screws connecting Service Fixture to Screws connecting Service Fixture to Ratio Beam and Load Cell frame Ratio Beam and Load Cell frame 323346 Figure 3 37 Service Fixture for 150g to Figure 3 38 Service Fixture for 510g to 4100g 410g Precision Load Cell attached to Precision Load Cell attached to Hanger Ratio Hanger Ratio Beam and Load Cell frame Beam and Load Cell frame 4 Adjust the Up Down Stop Screw so the groove is half way above and below the stop tab Close it completely then open it completely counting the turns then close it half way Pioneer Balance Service Manual 3 15 CHAPTER 3 MAINTENANCE PROCEDURES 3 3 11 Load Cell Reassembly Precision Balances gt s5 tafata ata Figure 3 39 Sideways Motion Figure 3 40 Two screws secure Magnet Half Stop Plate 5 Position the Sideways Motion 6 Position the Temperature Sensor Stop Plate so the small post in wires so they clear the opening on the the Ratio Beam is centered in bottom of the Magnet Half See the hole in the Stop Plate Then Figure 3 40 Install the Magnet Half in insert and tighten the two screws front of the Ratio Coil so screw holes and washers See Figure 3 39 align Insert the two screws and tighten them N 7 Carefully remove the tape from the Contact Board see Step 13 page 3 11 and re position the Contact
92. ted hole down Flexure Flexure Flexure See Figure 3 45 f gt 14 Install the two Ratio Beam Flexures with the elongated holes down 15 Remove the Service Fixture See Figures 3 37 and 3 38 Figure 3 45 Ratio Beam Flexures and Vertical Flexure 16 Position the Load Cell in the balance Housing See Figure 3 46 Insert and tighten the three screws Be sure the Load Cell is squarely mounted in the Housing Connect the cable from the Main PCB to the Position Sensor Board _ ou Cable from Main PCB to Position Sensor Board Figure 3 46 Insert the 3 screws to secure Precision Load Cell in Bottom Housing CHAPTER 3 MAINTENANCE PROCEDURES 3 3 11 Load Cell Reassembly Precision Balances 17 18 19 20 21 22 Adjust the Position Sensor Board follow steps 9 through 11 in Section 3 3 9 summarized here With the Weighing Pan in its normal position but the Housing off power on the balance The On Off switch is the middle button on the main PCB NOTE The Position Sensor Board contains an Optical Sensor which must be positioned in the Ratio Beam s center of travel for the balance to function properly Adjust the vertical position of the Position Sensor Board if it is too high or too low the display indicates Error 8 X Move it until the display indicates other than 8 X Then tighten the screws on the board See Figure 3 47 When adjustments are complete tig
93. th the Base Plate See Figure 3 111 4 Now carefully tighten the two mounting screws and re check alignment g a i Paris F i Teien Et El Alignment Area Figure 3 111 Load Cell Alignment to Base Plate 5 Install the Weigh Below Hook and screw at the bottom of the Base Plate See Figure 3 110 CHAPTER 3 MAINTENANCE PROCEDURES 3 3 29 Removal and Installation of the Block Style Load Cell PC Board 1 Remove the Load Cell from the Mounting Plate See previous section 2 Unsolder the Temperature Sensor Board wires See Figure 3 112 3 Unsolder the Position Sensor Assembly from the Block Style Load Cell PC Board Unsolder Position Sensor Assembly far pi m um a i a ipine eri derrit l 4 iit rn Ben etl aa PP ah in na a ttt rai agat ur Mey N re zu ue Re BR citi ye pun RD vee Di x bri are m vyr fa Load Cell Load Cell Unsolder Temperature Ratio Beam Cable Board Screw PC Board Sensor Wires Figure 3 112 Block Style Load Cell PC Board Item Locations 4 Disconnect the Ratio Beam cable See Figure 3 112 5 Remove the Load Cell Board Screw and change the Board See Figure 3 112 6 Install new board ensuring the slot in the board is inserted in the slot in the Load Cell Frame See Figure 3 113 CAUTION A N When screwing in first turn the self tapping Cell Board Screw in a counterclockwise direction until the first screw thread engages and then tighten it See Figure 3 1
94. the one holding the first centering pin See Figure 3 150 Do not use tools in this step Install the screws washers and nuts for the Ratio Beam Work gently to avoid stressing the Load Cell s internal flexures After installing the screws washers and nuts by hand hold the screw head with a screw driver while tightening the nuts for the Ratio Beam See Figure 3 151 Turn the Up Down Stop Screw to its Original position See Figure 3 152 Remove the Centering Pins They should fall out easily Move the contact board as shown in Figure 3 153 Be very careful Sane f A yi Temporary not to break the wires on the board Wires A Gf 2g Screw Note The screw changes from ope Ne eg o the upper to the lower hole on the Contat S yes ri ontac Contact Board before inserting it Board r bar Mb Contact into the hole on the Load Cell frame Figure 3 153 Repositioning the Contact Board and Screw CHAPTER 3 MAINTENANCE PROCEDURES 3 3 33 Installing the Load Cell PCB Temperature Sensor Position Sensor Assembly The Temperature Sensor Position Sensor and the Load Cell PCB can be installed as an assembly as follows at Position Sensor f Faiy m ps Load Cell PCB m DEENEN IM Pe ome Fa il 7 Fer te EE Fe PERT ri PER PT Dae ee Thea gt TORIL Bi Be A i be ed RER ti 1 Install the Load Cell PCB by fitting the groove on the left of a ap an En Tree tit re i Ut d i d
95. tion 3 Seconds InCal or InCal or InCal or 200 or InCal or Span Cal Mass g 50 or60 50 or 60 50 or 100 50 or 100 100 or 200 100 or 200 100 or 150 Lin CalMass g 20 50 50 100 DE 100 200 x 7 200 400 x Pan Diameter 3 5in 9cm 4 7 in 12 cm Pioneer Balances Service Manual 1 3 CHAPTER 1 GETTING STARTED 1 4 SPECIFICATIONS TABLE 1 4 SPECIFICATIONS GOLD MODELS EXTERNAL CALIBRATION a BE To capacity by subtraction 1000 or 2000 or 2000 or 1000 or 2000 or 2000 or span Cal Mass g 500 or 800 544 3000 4000 2000 3000 3000 500 2000 2000 1000 2000 Lin Cal Mass g 1000 2000 So 2 on 2000 3000 aon Pan Diameter 6 6 x 7 1in 16 8 x 18 cm TABLE 1 5 SPECIFICATIONS GOLD MODELS _ eee woos wane Paa Pwan Pym pyainc pyanc PHAN CS VER as Repeatability g 0 01 std dev ET Tare Range To capacity by subtraction Stabilization 3 Seconds 1000 or 2000 or 2000 or 1000 or 2000 or 2000 or span Cal Mass g 20007500 2000 3000 4000 2000 3000 4000 Lin Cal Mass g a Oox Ff x x x ao 6 6x7 1in 16 8x18cm Net Wt 10 0 Ib 4 5 kg 1 4 Pioneer Balances Service Manual CHAPTER 1 GETTING STARTED 1 4 SPECIFICATIONS TABLE 1 6 ADMISSIBLE AMBIENT CONDITIONS 50 F to 86 F 10 C to 30 C 80 rh to 30 C 15 10 8 14V ac 50 60 Hz 6VA or 9 5 20V dc 6W Use only in closed rooms 1 5 BALANCE OPERATION This section contains information on the basic opera
96. tion of the balance and mechanical descriptions of the Load Cell Exploded view drawings are included in Chapter 5 which identifies all replaceable components of the balance Allow one hour for each 5 F or 3 C temperature change before using the balance Following temperature stabilization allow an additional hour after turning the balance on for the balance to stabilize 1 5 1 OVERVIEW OF THE CONTROLS m aa N OT ene e 22 gt O T A Sa CE M es Yes Se Eee Figure 1 1 Pioneer Carat and Gold Series displays Pioneer Balances Service Manual 1 5 CHAPTER 1 GETTING STARTED 1 5 2 OVERVIEW OF THE CONTROLS TABLE 1 7 FUNCTIONS OF DISPLAY CONTROLS Short Press Turns balance on sets display to zero Long Press Turns balance off Short Press Menu mode Selects or accepts setting Short Press Steps through active units and modes Long Press Enters Menu Short Press Menu mode Steps through available settings Long Press Menu mode Exit menu or abort out of menu item Short Press Sends data Long Press Initiates Span Calibration 1 5 2 OVERVIEW OF THE DISPLAY INDICATORS PCSGN BHAA AAAAE komg o Figure 1 2 Pioneer Display Indicators TABLE 1 8 DISPLAY INDICATORS Indicates that the measured value has become stable Negative Indicator Center of Zero Indicator Standard 7 segment numeric characters Eight characters are available and are used for displaying weight values
97. two washers a silver colored one near the Flexure a black one near out u the screw n o ae 6 Move the Contact Board from the Figure 3 80 Elongated holes on Ratio Ratio Beam to the Load Cell frame Beam Flexures go on the bottom See Figures 3 78 and 3 80 Avoid breaking the fine wires CHAPTER 3 MAINTENANCE PROCEDURES 3 3 18 Reassembling Analytical Load Cells 7 Carefully insert the Magnet Half in front of the Ratio Coil Align the screw holes on its four corners Then insert and tighten the four screws See Figure 3 81 8 Install the Position Sensor Board leaving the screws finger tight Tip Position each screw before installing the board stand the Load Cell on the Service Fixture and lower the PSB into position with an Allen Key holding one screw See Figure 3 83 Solder points for white wires Figure 3 83 Position Sensor Board 9 Solder the two wires from the Temperature Sensor to the two solder points on the Position Sensor Board See Figure 3 83 It s not critical which wires goes to which solder point 10 Solder the 3 wire Ribbon Cable to the Figure 3 84 3 wire cable soldered to Contact Board See Figure 3 84 gu ii Contact Board 11 Install the Vane Make sure the post is centered and that the Vane is not rubbing See Figure 3 85 12 Remove the Service Fixture CHAPTER 3 MAINTENANCE PROCEDURES 3 3 18 Reassembling Analytical Load Cells 13 Inst
98. upler CHAPTER 3 MAINTENANCE PROCEDURES 3 3 23 InCal Motor Removal amp Replacement 4 Install the Coupler supplied with the replacement motor then rotate the Correct Angle Motor Shaft by hand until it is ina counter clockwise position See Figure 3 102 If the Coupler is not in the position shown remove the screw and coupler reposition as shown and tighten the screw on the Motor Shaft 833 F Tr Figure 3 102 Motor Shaft in counter clockwise position 5 Install the InCal Motor to the InCal Mechanism The Motor Shaft must be in the position shown in Figure 3 102 6 Secure the InCal Motor and InCal Motor Shield to the InCal Mechanism with the screws previously removed 7 Test the InCal Mechanism again as described in Section 3 3 21 8 If the test is successful re install the Load Cell See Section 3 3 19 3 3 24 InCal Mechanism Removal NOTE Replacement InCal Mechanisms are available assembled with the InCal Motor installed 1 Open the balance and remove the Load Cell as described earlier 2 Remove the three Mounting Screws from the InCal Mechanism See Figure 3 103 a a k z E z a y E E 5a bole u 5 5 zZ fEardeze EEIBEDELER El Figure 3 104 Removing the InCal Mechanism Z 3 Mounting Screws Figure 3 103 Mounting Screws holding InCal Mechanism 3 Slide the InCal Mechanism as shown to remove it See Figure 3 104 CHAPTER 3 MAINT
99. vicing the balance an operational test and various performance tests should be made to confirm that the balance meets specifications Turn the balance on and allow itto warm up After it reaches ambient temperature allow it to run for at least one more hour before performing these tests NOTE A N Make sure the test area is free from drafts and that the balance rests on a level and vibration free surface 4 1 1 TEST MASSES REQUIRED The masses required to test the Ohaus Pioneer balances must meet the requirements of ASTM Class 1 or OIML E1 Tolerance The mass values are listed in Table 4 1 TABLE 4 1 TEST MASSES REQUIRED CAPACITY g SPAN MASSES g LINEARITY MASSES g 65 20 50 110 50 100 210 100 200 150 100 150 310 150 300 410 100 200 400 510 200 500 1500 1000 1500 2100 1000 2000 3100 1500 3000 4100 1000 2000 4000 4100 2000 4000 4 2 Operational Test 1 Connect a functioning Power Adapter to the balance power receptacle located at the rear of the balance 2 Plug the Power Adapter into a suitable power source 4 3 Segment Display Test Turn the balance on and ensure that all segments are enabled and displayed briefly The balance s model number appears next followed by a software revision number This is a Segment Display Test Figure 4 1 is a full display test See Figure 4 1 PCSGN SHARAAAAE Kamgx Figure 4 1 Segment Display CHAPTER 4 TESTING 4 4 Performance Tests Precision and Anal
100. want 22er 3 53 3 159 Load Cell PCB Test Connector nee 3 54 3 160 Test Gonneelor Detalle eas eenieceaecaticeecieeeti rass 3 54 3 161 UP DOWN SIO SEreW era 3 54 4 1 SCUMENEDISPlay an ensure ee 4 1 4 2 Mass Placement Locations for Off Center Load Test cccceeeseeeeeeeeeeeeeeeees 4 3 4 3 Off Center Load Adjustment Screws on Analytical models 4 4 4 4 Off Center Load Adjustment Screws on Precision models 2222000222 0 4 4 4 5 Off Center Load AdjUStMent ccccccccsseeeeceeeseeecceeseeesseaeeeeeseeaseeesaeeeeessaneeeeseas 4 4 5 1 Precision Top Load Balance Housing amp Internal Parts cccccccsseeeeseeeeeeeeeneeeenees 5 2 5 2 Round Pan Block Style InCal Balance Housing amp Internal Parts 5 4 5 3 Square Pan Block Style Square Pan Balance Housing amp Internal Parts 5 6 5 4 Precision Draft Shield Balance with Draft Shield Housing amp Parts 5 8 5 5 Analytical Balance Housing amp Internal Parts u 2 uu02440022nnn nenne nenn nenne nennen 5 10 5 6 Precision Balance Load Cell amp Parts u00022240000nnennnnennnnnnennnennnne nennen ennennnn 5 12 5 7 Analytical Balance Load Cell amp Parts 22u00s222000snnennnennennnnnnnnnnnnnnnnnnnneennnnnnn 5 14 5 8 Block Style InCal Load Cell amp Parts nun aa 5 26 C 1 Com Port Gonfiguration Menu
101. ytical Balances Accurate performance of the Pioneer balances is determined by a series of four performance tests The displayed readings are compared with the tolerances listed in Tables 4 2 and 4 3 Tolerance values are expressed in counts A one count difference is shown in the last digit on the balance display TABLE 4 2 TOLERANCES PRECISION MODELS TOLERANCE COUNTS 0 TOLERANOE CONms O O Preisen mans ar TABLE 4 3 TOLERANCES ANALYTICAL MODELS Linearity mg 0 3 NOTE The following performance tests are used to evaluate balance operation before and after repairs The balance must meet the requirements specified in each test as well as the specifications listed in Tables 1 1 1 4 Before proceeding with the following tests the balance should be warmed up for at least five minutes and calibrated See Appendix A 4 4 1 Precision Test Precision and Analytical Balances The Precision Test measures the Standard Deviation of a set of similar weight readings which should match the specification for each model listed in Tolerance Tables 4 1 and 4 2 1 Tare the balance The reading on the display should be Og 2 Select a mass weighing near the maximum capacity of the balance and place it on the center of the Pan Observe and record the reading 3 Remove the mass The reading should return to Og 1 count 4 Repeat this test three times The reading should be within 1 count of the reading recorded

Service Manual - Test Equipment Depot

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