Pioneer Balances Service Manual

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 1.1 1.2 1.3

Introduction ...1-1 Service Facilities...1-1 Tools and Test Equipment Required ...1-2 1.3.1 Special Tools ...1-2 1.3.2 Standard Tools and Test Equipment ...1-2 1.4 Specifications...1-2 1.5 Balance Operation ...1-5 1.5.1 Overview of the Controls ...1-5 1.5.2 Overview of the Display Indicators ...1-6 1.5.3 Power On ...1-7 1.5.4 Power Off ...1-7 1.5.5 Menu Setup ...1-7 1.5.6 Menu Structure ...1-7 1.5.7 The Load Cell ...1-8 1.6 Connecting the RS232 Interface...1-9 1.7 RS232 Commands ...1-10

CHAPTER 2 TROUBLESHOOTING 2.1

Troubleshooting ...2-1 2.1.1 General Procedures for Troubleshooting ...2-1 2.2 Diagnostic Guide ...2-1 2.2.1 Diagnosis...2-1 2.3 Error Codes ...2-4

CHAPTER 3 MAINTENANCE PROCEDURES 3.1

Preventive Maintenance ...3-1 3.1.1 Preventive Maintenance Checklist ...3-1 3.2 Opening the Balance ...3-1 3.2.1 Variations in Opening Pioneer Models ...3-2 3.3 Load Cell Removal and Disassembly ...3-3 3.3.1 Variations in Pioneer Load Cells ...3-3 3.3.2 Disassembly of Precision Balances with Internal Calibration ...3-4 3.3.3 Removing Internal Calibration Weights ...3-5 3.3.4 Servicing the Internal Calibration Mechanism ...3-5 3.3.5 Reassembling the Internal Calibration Mechanism ...3-6 3.3.6 Disassembly of Precision Balances with InCal Mechanism ...3-6 3.3.7 Removing the Load Cell – Precision Balances...3-7 3.3.8 Load Cell Disassembly – Precision Balances ...3-8 3.3.9 Position Sensor Board Removal/Replacement/Adjustment – Precision...3-13 3.3.10 Main Printed Circuit Board (PCB) Replacement – All Balances...3-14 3.3.11 Load Cell Reassembly – Precision Balances ...3-15 3.3.12 Removing the InCal Mechanism from InCal Analytical Balances...3-19 3.3.13 Removing Internal Calibration Weights and Components...3-19 3.3.14 Re-Installing Internal Calibration Components ...3-21 3.3.15 Load Cell Removal/Installation – Analytical Balances...3-21 3.3.16 Disassembling Analytical Load Cells...3-22 3.3.17 Position Sensor PC Board Removal/Replacement/Adjustment - Analytical...3-28 3.3.18 Reassembling Analytical Load Cells ...3-29 3.3.19 Block Style Load Cell Removal & Replacement...3-34

TABLE OF CONTENTS Page No.

3.3.20 Block Style Load Cell Disassembly & Replacement with Load Cell Kit...3-35 3.3.21 Progressive Disassembly of Block Style Load Cells ...3-35 3.3.22 Internal Calibration Testing ...3-36 3.3.23 InCal Motor Removal & Replacement ...3-36 3.3.24 InCal Mechanism Removal...3-37 3.3.25 InCal Mechanism Installation ...3-38 3.3.26 Position Sensor Assembly Removal/Installation on MFR Load Cell ...3-39 3.3.27 Removing the Block Style Load Cell from the Base Plate...3-40 3.3.28 Installing the Block Style Load Cell on the Base Plate ...3-41 3.3.29 Removal and Installation of the Block Style Load Cell PC Board...3-42 3.3.30 Removing the Ratio Beam on Block Style Load Cells...3-43 3.3.31 Installing the Ratio Beam on Block Style Load Cells...3-47 3.3.32 Installing the InCal Weight Arm ...3-49 3.3.33 Installing the Load Cell PCB-Temperature Sensor-Position Sensor ...3-51 3.2.34 Setting the Up/Down Stop Screw on Block Style Load Cells ...3-53 CHAPTER 4 TESTING 4.1. Testing ...4-1 4.1.1 Test Masses Required ...4-2 4.2 Operational Test ...4-1 4.3 Segment Display Test...4-1 4.4. Performance Tests ...4-2 4.4.1 Precision Test...4-2 4.4.2 Off-Center Load Test...4-3 4.4.3 Off-Center Load Adjustment for Precision Models ...4-4 4.4.4 Off-Center Load Adjustment for Analytical Models...4-5 4.4.5 Off-Center Load Adjustment for Block Style Models ...4-6 4.4.6 Repeatability Test...4-7 4.4.7 Linearity Test...4-9

CHAPTER 5 DRAWINGS AND PARTS LISTS 5-1 5-2 5-3 5.4 5.5 5.6 5.7 5.8

Precision Top Load Balance Housing & Internal Parts...5-2 Round Pan Block Style InCal Balance: Housing & Internal Parts...5-4 Square Pan Block Style Square Pan Balance: Housing & Internal Parts ...5-6 Precision Draft Shield Balance with Draft Shield: Housing & Parts ...5-8 Analytical Balance: Housing & Internal Parts ...5-10 Precision Balance Load Cell & Parts ...5-12 Analytical Balance Load Cell & Parts ...5-14 Block Style InCal Load Cell & Parts...5-26

Appendix A STANDARD CALIBRATION A.1 Calibration... A-1 A.1.1 Calibration Masses ... A-1 A.2 Span Calibration ... A-1 A.3 Linearity Calibration ... A-2 Appendix B SERVICE CALIBRATION B.1 Entering the Service Menu ... B-1 B.2 Ramp ... B-1 B.3 Service Span Calibration ... B-2 B.4 Service Linear Calibration... B-3

TABLE OF CONTENTS Page No.

APPENDIX C SOFTWARE SERVICE TOOL INSTRUCTIONS C.1 Restore EEPROM Data ... C-2 C.2 Replace Load Cell ... C-3 C.3 Install new Main Printed Circuit Board... C-4 C.4 Update Software in the Balance ... C-5 C.5 Diagnostics ... C-6 C.5.1 Incal Weight Mechanism Testing ... C-6

LIST OF TABLES TABLE NO.

1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 2-1 2-2 4-1 4-2 4-3 4-4 5-1 5-2 5-3 5.4 5.5 5.6 5.7 5.8

TITLE

Page No.

Specifications: External Calibration Models (includes M Models) ...1-2 Specifications: Internal Calibration Models (C & CM) ...1-3 Specifications: Carat Models...1-3 Specifications: Gold Models (External Calibration) ...1-4 Specifications: Gold Models (Internal Calibration) ...1-4 Admissible Ambient Conditions...1-5 Functions of Display Controls...1-5 Display Indicators ...1-6 COM 1 Interface Pin Connections...1-9 RS232 Command Table...1-10 Diagnostic Guide ...2-2 Error Codes ...2-4 Test Masses Required ...4-1 Tolerances – Precision Models ...4-2 Tolerances – Analytical Models...4-2 Repeatability Worksheet ...4-8 Precision Top Load Balance Housing & Internal Parts ...5-3 Round Pan Block Style InCal Balance: Housing & Internal Parts ...5-5 Square Pan Block Style Square Pan Balance: Housing & Internal Parts...5-7 Precision Draft Shield Balance with Draft Shield: Housing & Parts...5-9 Analytical Balance: Housing & Internal Parts ...5-11 Precision Balance Load Cell & Parts...5-13 Analytical Balance Load Cell & Parts ...5-15 Block Style InCal Load Cell & Parts ...5-17 LIST OF ILLUSTRATIONS

FIGURE NO.

1-1 1-2 1-3 1-4 1-5 1-6 3-1 3-2 3-3 3-4 3-5 3-6 3-7

TITLE

Pioneer, Carat and Gold Series Displays...1-5 Pioneer Display Indicators...1-6 Pioneer Menu Structure ...1-7 Load Cell Assembly...1-8 COM 1 Connector ...1-9 Soldering points J1 and J2 ...1-9 Top panel lifts up and slides out...3-2 Groove in side panel’s base liner aligns with tab on Housing ...3-2 Precision Load Cell with Incal ...3-3 Analytical Load Cell with Incal...3-3 Precision Load Cell ...3-3 Analytical Load Cell...3-3 Precision Block Style Load Cell with InCal...3-4

TABLE OF CONTENTS 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

TITLE

Page No.

Analytical Block Style Load Cell with InCal ...3-4 Precision Balance with InCal Mechanism ...3-4 InCal Weight Cover removed ...3-5 Bottom Housing with Load Cell, Weight Arms and Weights removed...3-5 InCal Motor removed from its Housing...3-6 Screws securing Weight Arm assembly ...3-6 Proper manner to grasp Load Cell when removing Weight Arm assembly...3-7 Cable connects to Position Sensor Board...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 Cell top ...3-8 Precision Load Cell bottom ...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 Bent Flexure ...3-9 Position Sensor Board...3-10 Contact Board with ribbon cable ...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 Hanger ...3-10 Two screws secure Magnet Half ...3-11 Sideways Motion Stop Plate...3-11 Ratio Beam clearing stop on Up/Down Stop Screw as it is lifted out ...3-12 Magnets must be clean ...3-12 Position Sensor Board...3-13 Adjust position of Sensor Board until Err8.X does not appear ...3-13 Position Sensor Board...3-14 Installing Ratio Beam, clearing the Up/down Stop Screw ...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 Motion Stop Plate...3-16 Two screws secure Magnet Half ...3-16 Contact Board ...3-16 Solder points on Position Sensor Board...3-16 Precision Load Cell top ...3-17 Precision Load Cell bottom ...3-17 Ratio Beam Flexures and Vertical Flexure...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 Mechanism...3-19 InCal Weight Covers removed ...3-19 Bottom Housing with Load Cell, Weight Arms and Weights removed...3-20 InCal Motor removed from its assembly...3-20 InCal Motor Cam in correct position for reassembly ...3-20 Cable connects to the Position Sensor Board...3-21 On Analytical balances, the 3 screws securing Load Cell are on bottom...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

TABLE OF CONTENTS LIST OF ILLUSTRATIONS 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 3-75 3-76 3-77 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

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 ...3-23 Vertical Flexure and screws, Lock Plate, washers, and bushings, removed...3-23 Top Flexure Arm (Analytical)...3-23 Bottom Flexure Arm (Analytical)...3-23 Hanger with two screws ...3-25 Service Fixture attached to the front of Load Cell after removing Hanger ...3-25 The Vane is secured by two screws near the rear of the Load Cell ...3-25 The Vane removed...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 ...3-26 Four screws secure the Magnet Half to the Ratio Beam...3-26 The Magnet Half, when removed, should be cleaned ...3-25 A screw connects the Contact Board to the Load Cell ...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)...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 ...3-29 Elongated holes on Ratio Beam Flexures go on the bottom ...3-29 Installing the Magnet Half...3-30 Four screws on Magnet Half ...3-30 Position Sensor Board...3-30 3-wire cable soldered to Contact Board ...3-30 Installing the Vane...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 Bottom Flexure Arm ...3-31 Top Flexure Arm...3-31 Vertical Flexure ...3-31 Vertical Flexure and screws, Lock Plate, washers, and bushings, removed...3-31 Analytical InCal Load Cell with Top Bracket visible...3-32 Analytical balance Load Cell with Top Bracket visible ...3-32 Bottom Mounting Plate on Analytical Load Cell ...3-32 Ribbon cable connects PSB to Main PCB...3-32 When Position Sensor Board shows normal weight, tighten its screws ...3-33 Block Style Load Cell ...3-34 Service Toolset for Block Style Load Cells. PN 476000-030 ...3-35 InCal Motor...3-36 InCal Motor Removal...3-36 Motor Coupler ...3-36 Motor Shaft in counter-clockwise position ...3-37 Mounting Screws holding InCal Mechanism ...3-37 Removing the InCal Mechanism ...3-37 InCal Mechanism Alignment...3-38 Centering InCal Weight ...3-38

TABLE OF CONTENTS LIST OF ILLUSTRATIONS 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

TITLE

Page No.

Removing Position Sensor ...3-39 Ratio Beam Pin Alignment ...3-39 Base Plate Removal...3-40 Load Cell Mounting Components ...3-41 Load Cell Alignment to Base Plate...3-41 Block Style Load Cell PC Board Item Locations ...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 Sensor ...3-43 Removing Temperature Sensor ...3-43 Load Cell PCB...3-44 Contact Board Cover is removed by squeezing the plastic post ...3-44 Contact Board with cover holder off ...3-44 Centering Pins...3-44 Centering Pins Installed ...3-44 Contact Board Location...3-45 Contact Board with cover holder off ...3-45 Loosening Ratio Beam Nuts...3-45 Ratio Beam Screws and Washers removed...3-45 Loosening InCal Weight Arm nuts...3-46 Weight Arm Screws and Washers removed...3-46 InCal Weight Arm removal ...3-46 InCal Weight Arm removed ...3-46 Aluminum Sleeves removed...3-47 Up/Down Stop Screw ...3-47 Centering Pins removed...3-47 Removing the Ratio Beam ...3-47 Ratio Beam Removed ...3-47 Removing the Ratio Beam ...3-47 Ratio Beam Removed ...3-47 Removing the Aluminum Sleeves ...3-47 Ratio Beam Weight Removal ...3-48 Load Cell Critical Area...3-48 Magnet Area...3-48 Ratio Beam Vane Slotted Area ...3-49 Four Ratio Beam sleeves are larger than the four Weight Arm sleeves ...3-49 Replacing the Ratio Beam...3-49 Positioning the Ratio Beam over the Magnet ...3-49 Centering Pin goes into first hole after upward bend in Ratio Beam...3-49 InCal Weight Arm before insertion ...3-50 Inserting InCal Weight Arm ...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...3-51 Tightening Ratio Beam nuts ...3-51 Up/Down Stop Screw ...3-51 Repositioning the Contact Board and Screw...3-51 Load Cell PCB, Temperature Sensor and Position Sensor...3-52 Groove on left of PCB fits tab on Load Cell frame ...3-52

TABLE OF CONTENTS LIST OF ILLUSTRATIONS FIGURE NO.

TITLE

Page No.

3-156 Temperature Sensor extends into a hole in the Magnet ...3-52 3-157 Position Sensor on the Magnet ...3-53 3-158 Pin centered in PSB ...3-53 3-159 Load Cell PCB Test Connector ...3-54 3-160 Test Connector Detail...3-54 3-161 Up/Down Stop Screw ...3-54 4-1 Segment Display ...4-1 4-2 Mass Placement Locations for Off-Center Load Test ...4-3 4-3 Off-Center Load Adjustment Screws on Analytical models...4-4 4-4 Off-Center Load Adjustment Screws on Precision models ...4-4 4-5 Off-Center Load Adjustments...4-4 5-1 Precision Top Load Balance Housing & Internal Parts...5-2 5-2 Round Pan Block Style InCal Balance: Housing & Internal Parts...5-4 5-3 Square Pan Block Style Square Pan Balance: Housing & Internal Parts ...5-6 5.4 Precision Draft Shield Balance with Draft Shield: Housing & Parts ...5-8 5.5 Analytical Balance: Housing & Internal Parts ...5-10 5.6 Precision Balance Load Cell & Parts ...5-12 5.7 Analytical Balance Load Cell & Parts ...5-14 5.8 Block Style InCal Load Cell & Parts...5-26 C-1 Com Port Configuration Menu... C-1 C-2 The Software Service Tool’s Restore EEProm Tab ... C-2 C-3 The Software Service Tool’s Replace Load Cell Tab... C-3 C-4 The Software Service Tool’s Replace PCB Tab... C-4 C-5 The Software Service Tool’s Download Software Tab ... C-5 C-6 The Software Service Tool’s Diagnostics Tab... C-6

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 components. 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: •

Should be temperature controlled and meet the balance specifications for temperature environmental requirements. See specifications for temperature ranges of the various models.

•

Must be free of vibrations such as fork lift trucks close by, large motors, etc.

•

Must be free of air currents or drafts from air conditioning/heating ducts, open windows, people walking by, fans, etc.

•

Area must be clean and air must not contain excessive dust particles.

•

Work surface must be stable and level.

•

Work surface must not be exposed to direct sunlight or radiating heat sources.

•

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

1. Digital Voltmeter (DVM) – Input impedance at least 10 megohms in 1 V DC position. 2. Nutdriver, 6mm 3. Hex or Allen key wrenches, metric. 4. Other assorted hand tools, tweezers, adjustable open wrenches, etc. 5. Soldering iron (50 watt) and solder (rosin core solder, not acid core). 6. 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) MODEL

PA64 PA114 PA214 PA153 PA213 PA313 PA413 PA512 PA1502 PA2102 PA4102 PA4101

Capacity (g)

65

110

210

151

210

310

410

510

1510

2100

4100

4100

Readability (g)

0.0001

0.001

0.001

0.01

0.1

Repeatability (mg)

0.1 (std. dev.)

1

1 (std. dev.)

10 (std. dev.)

100 sd

±0.003

±0.03

±0.3

Linearity (g)

±0.0003

OCL ½ cap ½ dist 0.1mg 0.2 mg 0.3 mg

3 mg

30 mg

Tare Range

To capacity by subtraction

Stabilization

3 Seconds

40 mg

200 mg

Span Cal Mass (g)

50 or 60

50 or 100

100 or 100 or 100 or 200 150 200

200 or 200 or 200 or 1000 or 300 400 500 1500

1000 or 2000

2000 or 4000

Lin. Cal Mass (g)

20, 50

50, 100

100, 200

150, 300

1000, 2000

2000, 4000

Pan Diameter Net Wt

3.5 in / 9 cm

100, 150

100, 200

4.7 in / 12 cm 10 lb / 4.5 kg

200, 400

200, 500

1000, 1500

7.1 in / 18 cm 7.3 lb / 3.3 kg

CHAPTER 1 GETTING STARTED 1.4

SPECIFICATIONS TABLE 1-2. SPECIFICATIONS: INCAL MODELS (C & CM)

MODEL

PA64C

PA114C

PA214C

PA213C

PA413C

PA512C

PA2102C

PA4102C

PA4101C

Max (g)

65

110

210

210

410

510

2100

4100

4100

Min (g)

0.1

0.2

d = (g)

0.0001

0.001

e = (g)

0.001

0.01

Approval

Class 1

Repeatability (mg) Linearity (g) OCL ½ cap ½ dist

5 0.01 0.1 Class 2

0.1 (std. dev.)

1 (std. dev.)

10 (std. dev.)

±0.0003

±0.003

±0.03

0.2mg

0.3mg

2mg

3mg

20mg

Tare Range

To capacity by subtraction

Stabilization

3 Seconds

Span Cal Mass (g)

50 or 100

50 or 60

Pan Diameter

0.1

100 or 200

100 or 200

3.5 in / 9 cm

200 or 400

200 or 500

30mg

1000 or 2000

4.7 in / 12 cm

Net Wt

2000 or 4000

7.1 in / 18 cm

10 lb / 4.5 kg

TABLE 1-3. SPECIFICATIONS: CARAT MODELS MODEL

PAJ303

Capacity (g)

PAJ303C

PAJ603

65

PAJ603C

PAJ1003

120

PAJ1003C PAJ2003 PAJ2003C 210

400

Readability (g)

0.001

0.01

Repeatability (mg)

0.1 (std. dev.)

1 (std. dev.)

Linearity

±0.003

OCL ½ cap ½ dist

0.2mg

±0.003 0.1mg

±0.03

0.2mg

0.3mg

Tare Range

To capacity by subtraction

Stabilization

3 Seconds

0.2mg

Span Cal Mass (g)

50 or 60

InCal or 50 or 60

50 or 100

InCal or 50 or 100

100 or 200

InCal or 100 or 200

200 or 400

InCal or 100 or 150

Lin. Cal Mass (g)

20, 50

X

50, 100

X

100, 200

X

200, 400

X

Pan Diameter

3.5 in / 9 cm

Net Wt

Pioneer™ Balances Service Manual

10 lb / 4.5 kg

1-3

4.7 in / 12 cm

CHAPTER 1 GETTING STARTED 1.4

SPECIFICATIONS TABLE 1-4. SPECIFICATIONS: GOLD MODELS (EXTERNAL CALIBRATION)

MODEL

PAJ812

PAJ2102

PAJ3102

PAJ4102

PAJ2101

PAJ3101

PAJ4101

Capacity (g)

810

2100

3100

4100

2100

3100

4100

Readability (g)

0.01

0.1

Repeatability (g)

0.01 (std. dev.)

0.1 (std. dev.)

±0.03

±0.2

Linearity (g) OCL ½ cap ½ dist

0.3mg

0.4mg

2mg

Tare Range

To capacity by subtraction

Stabilization

3 Seconds

Span Cal Mass (g)

500 or 800

1000 or 2000

2000 or 3000

2000 or 4000

1000 or 2000

2000 or 3000

2000 or 3000

Lin. Cal Mass (g)

500, 800

1000, 2000

2000, 3000

2000, 4000

1000, 2000

2000, 3000

2000, 4000

Pan Diameter

6.6 x 7.1 in / 16.8 x 18 cm

Net Wt

10 lb / 4.5 kg TABLE 1-5. SPECIFICATIONS: GOLD MODELS (INTERNAL CALIBRATION)

MODEL

PAJ812C

PAJ2102C

PAJ3102C

PAJ4102C

PAJ2101C

PAJ3101C

PAJ4101C

Capacity (g)

510

2100

3100

4100

2100

3100

4100

Readability (g)

0.01

0.1

Repeatability (g)

0.01 (std. dev.)

Linearity (g)

±0.03

±0.03

±0.03

Tare Range

To capacity by subtraction

Stabilization

3 Seconds

±0.03

Span Cal Mass (g)

200 or 500

1000 or 2000

2000 or 3000

2000 or 4000

1000 or 2000

2000 or 3000

2000 or 4000

Lin. Cal Mass (g)

X

X

X

X

X

X

X

Pan Diameter

6.6 x 7.1 in / 16.8 x 18 cm

Net Wt

10.0 lb / 4.5 kg

1-4

Pioneer™ Balances Service Manual

CHAPTER 1 GETTING STARTED 1.4

SPECIFICATIONS TABLE 1-6. ADMISSIBLE AMBIENT CONDITIONS

Temperature range

50°F to 86°F / 10°C to 30°C

Atmospheric humidity

80% rh @ to 30°C

Voltage fluctuations

-15% +10%

Installation category

II

Pollution degree

2

Power supply voltage

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 operation 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

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

1.5.2

Button

Action

Functions

O/T – On Off Yes

Short Press: Long Press: Short Press (Menu mode):

Turns balance on, sets display to zero Turns balance off Selects or accepts setting

Unit Menu No

Short Press: Long Press: Short Press (Menu mode): Long Press (Menu mode):

Steps through active units and modes Enters Menu Steps through available settings Exit menu or abort out of menu item

Print Cal

Short Press: Long Press:

Sends data Initiates Span Calibration

OVERVIEW OF THE DISPLAY INDICATORS 1

5 2

Figure 1-2. Pioneer Display Indicators. 3

4

TABLE 1-8. DISPLAY INDICATORS No. Function 1

Indicates that the measured value has become stable.

2

Negative Indicator

3

Center of Zero Indicator

4

Standard (7) segment numeric characters. Eight characters are available and are used for displaying weight values.

5

Symbols for weighing modes, include: g - Grams, kg - Kilograms, mg - Milligrams, ct- Carats, N - Newtons, lb - 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 >O/T<. 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 >O/T< 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

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 NAVIGATION – 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 Permanent 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.

Vane

Force Coils

Counter Weight

Ratio Beam

Pan

Upper Flexure Arm Top Bracket

Position Sensor

Hanger Ratio Beam Flexure

Temperature Sensor Printed Circuit Board

Vertical Flexure

Magnet

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). 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

4

5 9

2

3 8

7

1

Zero/Tare*

J1*

Print*

J2*

COM 1 Pin Connections 1 – Remote Tare 2 – TxD 3 – RxD 4 – Not used 5 – Ground 6 – Not used 7 – CTS 8 – RTS 9 – Remote Print

6

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

Function

IP

Immediate print the displayed weight (stable or unstable).

P

Print and displayed weight (stable or unstable).

CP

Continuous Print. OP ends continuous print.

AS

Auto print on stability

xP

Interval Print x = Print Interval (1-3600 seconds) OP ends Interval Print.

T

Same as pressing Zero/Tare key.

PU

Print current weighing unit.

OFF

Turns balance OFF.

ON

Turns balance on.

PSN

Print Serial Number.

PV

Print version: name, software revision and LFT ON (if LFT is set on).

x#

Set PC reference weight (x) in grams. (Must have been a APW stored.)

P#

Print PC reference weight.

x%

Sent % reference weight (x) in grams. (Must-have reference weight stored.)

P%

Print percent reference weight.

0PF

Stop (zero) the old Adventurer print format, begin to use the default print format

1PF

Stop using the default print format, begin to use the old Adventurer print format

0S

(zero) Stable off

SS

Stable on (default)

0RL

Stops the scale from sending “OK” in response to instruction (non-print) commands.

1RL

Returns scale to default mode of sending “OK”.

1-10

Pioneer™ Balances Service Manual