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OHAUS EXPLORER, Service Manual

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OHAUS EXPLORER Service Manual Download Page 11

1-1

CHAPTER 1 INTRODUCTION

1.1 INTRODUCTION

This service manual contains the information needed to perform routine maintenance and service on the Ohaus Explorer

®

,

Explorer Pro

®

 and Voyager

®

 balances.  There are three basic configurations of balances: Analytical, Precision Top Loader

and High Capacity Top Loader.  The High Capacity Top Loader balances are rated from 12,000 grams to 32,000 grams
capacity and contain different components than the lower capacity Precision Top Loader balances.  The procedures in this
manual assume the technician performing them has a working knowledge of the use of standard hand tools and the repair
and use of precision instruments.

The service strategy for Explorer balances is the replacement of PC boards, membrane switches and most case parts.  The
transducers are to be repaired.  Only parts listed in the parts list are replaceable.

To service an Explorer Pro or Voyager balance, the display module must be removed and an Explorer display module
substituted.  This is required in order to use the service software that is in the processor that is located on the Main PCB.
See illustration below.

Explorer

  PRECISION

Explorer 

Pro

Voyager

             PRECISION

0.00

BASIC WEIGHING

0%

100%

GRAMS

STABLE

Enter

Go Back

Heip

Print

>O/T<

>O/T<

PRESS   <ENTER>   FOR MENU

             PRECISION

>O/T<

>O/T<

Enter

Go Back

Help

Print

OHAUS

®

0.000

BASIC WEIGHING

0%

100%

GRAMS

STABLE

PRESS   <ENTER>   FOR MENU

*R%DFN

+HOS

3ULQW

(QWHU

2Q2II

0.0

WEIGHT

0%

100%

CONTRAST

GRAMS

STABLE

MOVE HIGHLIGHT

CONTRAST

MAIN MENU

ANALYTICAL

ANALYTICAL

HIGH CAPACITY

HIGH CAPACITY

HIGH CAPACITY

Display Module

Display Module

>O/T<

>O/T<

OHAUS

®

Stable 

  g

Print

Setup

Units

Mode

Enter

Summary of Contents for EXPLORER

Page 1: ...Ohaus Corporation 19A Chapin Road P O Box 2033 Pine Brook NJ 07058 2033 973 377 9000 SERVICE MANUAL EXPLORER BALANCES EXPLORER PRO BALANCES VOYAGER BALANCES ...

Page 2: ......

Page 3: ...ANCES VOYAGER BALANCES O T O T OHA US Sta ble g Prin t Set up Uni ts Mo de Ent er O T O T O T O T OHAU S Sta ble g Prin t Setu p Unit s Mod e Ente r R DFN HO S 3UL QW QW HU 2Q2 II 0 0 WE IGH T 0 100 CO NT RA ST GR AM S ST AB LE MO VE HIG HL IGH T CO NT RA ST MA IN ME NU 0 00 BA SIC WEIGH ING 0 100 GR AM S ST AB LE Ent er Go Bac k Hei p Prin t O T O T PR ES S E NT ER FO R ME NU O T O T Ente r Go Ba...

Page 4: ......

Page 5: ...Load Flexure Vertical Link Installation 3 4 3 1 7 Analytical Load Cell Upper Flexure Arm and Lower Flexure Arm Removal Installation 3 5 3 1 8 Removing the Lever and Coil 3 6 3 1 9 Replacing the Vertical Flexures Pillow Block Bearings 3 6 3 1 10 Replacing the Lever and Coil 3 7 3 1 11 Monoblock Load Cell Removal Precision Top Loader Balance and Analytical 3 7 3 1 12 Monoblock Load Cell Replacement ...

Page 6: ...r Components 3 19 3 2 1 Analytical Balances Main Printed Circuit Board PCB 3 19 3 2 2 Analytical Balance Position Sensor PC Board 3 21 3 2 3 Precision Top Loader Balances Main Printed Circuit board PCB 3 21 3 2 4 High Capacity Top Loader Balance Main Printed Circuit Board PCB and Power Supply PCB 3 23 3 2 5 High Capacity Top Loader Balance Connector Printed Circuit Board PCB 3 24 3 2 6 Removing th...

Page 7: ...mitations A 1 A 3 Installing EP Loader Software A 1 A 4 Run EP Loader Software A 1 A 5 Setup the Balance in Manufacturing Mode A 2 A 6 Connect the Balance to a PC A 2 A 7 Personality Data Label Entry A 3 A 8 Temperature Compensation TC Data Entry A 5 A 9 Downloading Personality Data and or TC Data into the Balance A 7 A 10 Saving Personality Data and TC Data A 7 A 11 Opening Data Files A 7 A 12 Cl...

Page 8: ...oblock Load Cell Parts List 5 11 5 6 High Capacity Top Loader Balance Parts List Sheet 1 5 13 5 6 High Capacity Top Loader Balance Parts List Sheet 2 5 15 5 7 Monoblock High Capacity Top Loader Parts List 5 17 5 8 Explorer Display Parts List 5 19 5 9 Explorer High Capacity Parts List 5 21 5 10 Explorer Pro Voyager Display Parts List 5 23 5 11 Voyager Explorer Pro High Capacity Parts List 5 25 TABL...

Page 9: ...12 3 17 Monoblock Mounting 3 12 3 18 Position Sensor Connections 3 13 3 19 Calibration Motor Removal 3 14 3 20 Position Sensor Assembly Mounting 3 15 3 21 Force Coil Removal 3 15 3 22 Force Coil Lever Installation 3 16 3 23 Installation Monoblock and Position Sensor 3 16 3 24 Servomotor Installation 3 17 3 25 Position Sensor Connections 3 18 3 26 Display Removal Installation for Explorer Precision...

Page 10: ... 5 6 Overall Exploded of High Capacity Top Loader Balance Sht 1 5 12 5 6 Overall Exploded of High Capacity Top Loader Balance Sht 2 5 14 5 7 Exploded View of Monoblock Load Cell for High Capacity Top Loader Balance 5 16 5 8 Exploded View of Explorer Display 5 18 5 9 Exploded View of Explorer High Capacity Display 5 20 5 10 Exploded View of Explorer Pro Voyager Display 5 22 5 11 Exploded View of Vo...

Page 11: ...aneswitchesandmostcaseparts The transducers are to be repaired Only parts listed in the parts list are replaceable To service an Explorer Pro or Voyager balance the display module must be removed and an Explorer display module substituted This is required in order to use the service software that is in the processor that is located on the Main PCB See illustration below Explorer PRECISION Explorer...

Page 12: ...xplorer Pro balance in a manufacturing mode to download temperature and personality data Appendix C Production Mode Calibration Contains calibration information in a production mode Before servicing the balance you should be familiar with the Instruction Manual which is packed with every balance 1 2 SERVICE FACILITIES DO NOT SERVICE the balance Next to open windows or doors causing drafts or rapid...

Page 13: ... Metric 4 Box wrench 7mm 5 Nutdriver 3 16 6 Hex or Allen key wrenches 7 16 9 64 or 3 32 M3 SAE and Metric Set 7 Other assorted hand tools tweezers adjustable open wrenches etc 8 Soldering iron 50 watt and solder rosin core solder not acid core 9 Solderremover 10 Computer with at least 1 com port 11 A communications program similiar to Hyper Terminal supplied with Windows 1 4 TEST MASSES REQUIRED T...

Page 14: ...ty drift PPM C 3 10 C 30 C Operating temperature range w internal calibration 10 to 40 C 50 to 104 F w o internal calibration 10 to 30 C 50 to 86 F Power requirements External Adapter 100 120 V ac 220 V ac 50 60 Hz Plug configuration for US Euro UK Australia 1 5 SPECIFICATIONS Complete specificatons for the Ohaus Explorer balances are listed in Tables 1 2 1 3 and 1 4 When a balance has been servic...

Page 15: ...nual to familiarize yourself with the balance components and operation Do not attempt repairs unless you fully understand the operation of the balance 2 2 1 Diagnosis 1 Isolate and identify the symptom 2 Refer to Table 2 1 Diagnostic guide and locate the symptom 3 Follow the suggested remedies in the order that they appear 4 Perform the indicated checks or see the appropriate section of the manual...

Page 16: ...n Balance drifts When balance is turned ON CAL shows on the display Error3 0onahighcapacity 12000g 32000g balance Highcapacity 12000g 32000g bal ance will not turn on VoyagerLowandHighcapacityunits start in Print menu Incorrectweightreading RS232 interface not working Randomsegmentsdisplayedordis play locks up REMEDY Check replace power cord connec tions Check display module connections Replace di...

Page 17: ... If the error persists replace the PCB Displays Error 1 1 Temperaturechanneldutycycleoutofrange Failedtemperaturesensororbrokenwirebetweenthetemperaturesensor and the PCB Displays Error 2 0 Unable to stabilize within time limit after pressing the tare button Look for something touching any moving part of the transducer Could be a problem with the transducer itself Displays Err 3 0 Thezerohaschange...

Page 18: ...theTCdata If the problem still persists the main PCB must be reconfigured at Ohaus Displays Err 9 8 User calibration data failed checksum Perform MFG Calibration For units with internal calibration also perform MFGWT Displays Err 9 9 Can not be fixed in the field the unit has to be temperature compensated TABLE 2 2 EXPLORER VOYAGER ERROR CODES Cont TABLE 2 3 INFORMATION MESSAGES CALNOW IfInCALTM i...

Page 19: ...Err 3 2 Incal motor has not stopped in time Check motor motor control and weight positioning setup Displays Error 8 0 Error 8 1 This is a hardware error It could be caused by the PCB Transducer or the inter connections Displays Err 8 3 Power on load out of range Overload extra weight on pan Displays Err 8 4 Power on load out of range Pan missing or wrong pan that is too light Displays Err 8 5 Inte...

Page 20: ...haus Displays Err 9 5 Factory calibration data failed checksum Perform MFG and MFGWT If the problem persists reload the TC data If the problem still persists the main PCB must be reconfigured at Ohaus Displays Err 9 8 Usercalibrationdatafailedchecksum PerformMFGCalibration ForunitswithinternalcalibrationalsoperformMFGWT Displays Err 9 9 Can not be fixed in the field the unit has to be temperature ...

Page 21: ... 3 on top of the PC Board 11 8 Remove the Hex Screws 14 and Washers 25 at the rear of the balance which secure the connectors on the PC Board 11 9 Disconnect the two cable connectors from the Load Cell going to J3 and J6 on the PC board as shown on Figure 5 3 The Load Cell 9 If internal calibration option is installed disconnect cable to J4 10 Carefully lift the PC Board 11 from the Base 18 there ...

Page 22: ...dge connectors J3 J6 and the Sensor Cable The Sensor Board Cable is located at the rear of the balance and may interfere with the operation of the balance if it is not positioned away from the Load Cell Dress the cables and make sure that the cables do not interfere with the Load Cell If calibration option is installed connect cable to J4 CAUTION Do not touch any connectors on Main or Position Sen...

Page 23: ... to the two terminal contacts located on the right hand side of the Sensor Board 51C See Figure 5 4 as follows Black or ground test lead to the negative terminal on the Sensor PC Board Red or positive test lead to the positive terminal on the Sensor PC Board ADJUSTMENT SCREWS SENSOR PC BOARD PRECISION RESISTOR CONNECTIONS SENSOR CABLE CONNECTIONS Figure 3 1 Analytical Sensor Board Adjustment Locat...

Page 24: ... Flexure Vertical Link Removal 1 ToprotecttheFlexureattheHanger looselyinsert two mounting screws a Do not tighten 2 Loosen the lower flexure screw while holding the Torsion Protector b 3 Unscrew the upper screw c 4 Unscrew the lower screw and remove the flexure and spacers Figure 3 3 Removing the Vertical Flexure 3 1 4 Analytical Load Cell Position Sensor Adjustment Without Test Points 3 1 6 Anal...

Page 25: ...Bottom Mounting Plate a This is necessary to prevent further damage from occuring when trying to re move and replace individual Flexures 6 Take the two Screws removed from the Platform Mounting Assembly and install them in the Cen ter Post through the slots in the Shims Finger tighten the screws 7 FullytightenthetwoscrewswhichholdtheShims in place NOTE Do not remove the Upper or Lower Flexure Arms...

Page 26: ...ith the slot 6 Remove the Lateral Stop g 7 Unsolder the contact strips at the Lever board 8 Remove the screws from the vertical guides pil low block bearings from the chassis And lift the Lever out Figure 3 7 Lever Removal Installation 3 1 9 Replacing the Vertical Flexures Pillow Block Bearings 1 Place the Lever on a flat surface and remove the bad Flexures 2 The round hole of the Flexure goes to ...

Page 27: ...Remove the fixture Figure 3 9 Installing Lever and Coil 3 1 11 Monoblock Load Cell Removal Precision Top Loader Balance and Analytical Refer to Figures 5 1 and 5 3 in Chapter 5 for location of components called out in this procedure To remove the Monoblock Load Cell proceed as follows See Figure 5 1 for steps 1 through 5 1 With the balance turned OFF and unplugged remove the Pan 1 2 Remove Wind Sh...

Page 28: ... 18 Figure 5 3 so that there is equal space on both sides of the Monoblock load Cell to the base sides This is very important as the Balance will not function properly and may drift 2 Secure the Monoblock Load Cell to the Base 9 with the three Screws 24 Washers 23 previously removed at the bottom of the Base 18 Make sure the Monoblock Load Cell is properly aligned before tightening the screws 3 In...

Page 29: ...totheMonoblockandremovetheoverloadprotection 2 Unscrew the three fastener screws of the Position Sensor Assembly 3 Raise the Position Sensor Assembly which is held by the magnetic field 4 If the Position Sensor Assembly has to be changed unsolder Flexible Board 1 see Figure 3 10 1 102 POSITION SENSOR ASSEMBLY Figure 3 10 Removing Position Sensor Assembly from Monoblock ...

Page 30: ...d Cell Board screw and change board CAUTION Whenscrewingin firstturntheself tappingcell boardscrewinacounterclockwisedirectionuntilthefirst screw thread engages and then tighten it 210 1 2 3 Figure 3 12 Changing Load Cell Board 102 1 Figure 3 11 Position Sensor Assembly Mounting 1 Mount Position Sensor Assembly align centrally on the lateral stop pin 1 Figure 3 11 of the lever and fasten with the ...

Page 31: ...centering pins 1Aand 1B from the service tool set in the holes provided See Figure 3 15 NOTE Ascrewmaybeinstalledinthehole 1A this isadditionaloverloadprotection Turnit1 4turnand remove it 8 Remove screw 4 from Load Cell Board and removeLoadCellBoardTemperatureBoard Assembly and Position Sensor Assembly 9 Carefully undo Nuts 2 in the direction shown by the arrow while holding the SCREW HEADS to pr...

Page 32: ...ad lever only in the direction shown by the arrow to ensure the flexible bearings are not compressed 5 Attach Load Cell Board Temperature Sensor Board and Position Sensor Assem bly and tighten screws 6 Hold contact board to ensure the fine coil wires can not tear off Then as described in paragraph 3 1 16 remove the screw 2 from theleverandscrewtoholder SeeFigure3 14 7 Take out centering pins 8 Scr...

Page 33: ...e voltage value 2 Push down on overload protection until Lever is at the top of the vertical stop and then release overload protection Voltage value should be equal and opposite 3 If the two voltage values either side of zero are not of the same magnitude but e g 2 Volts and 1 6 Volts the vertical stop must be adjusted until the values are symmetrical Voltage range 1 8 2 5 Volts Asymmetry max 0 2 ...

Page 34: ...the Base 19 11 Remove the Weigh Assembly 20 from the Base 19 To remove the Monoblock 23 from the Weigh Assembly 20 continue as follows 12 Loosen the four Hex Head Screws 22 7 5 mm on the Weigh Assembly 20 These screws secure the Weigh Assembly to the Monoblock 23 13 Loosen the four Screws 24 which secures the U Block 25 to the Monoblock 23 14 Remove the Monoblock 23 Figure 3 19 Calibration Motor R...

Page 35: ...nce 1 Unscrew Contact Board b at the side Use care as the coil wires could break 2 Insert the Centering Pins c in the holes pro vided 3 Lift the Cover Plate d held in place by a magnetic field over the coil form 4 Carefully unscrew Lever Screws a while se curing the Locking Nuts on the opposite side Remove screws 5 Take out Centering Pins c 6 Notethepositionoftheheightadjustmentscrew f Turn the he...

Page 36: ... 27 3 1 25 Installing Monoblock and Assembling Position Sensor for High Capacity Top Loader Balance 1 Place Monoblock and formed chassis turned by 180 degrees on a flat and clean bench surface 2 Screw Monoblock to formed chassis Ensure top edge of formed chassis is flush with the top of the Monoblock See Figure 3 23 NOTE Tightening torque 4 0 Nm 3 Install Calibration Motor eccentric in top posi ti...

Page 37: ... the newmotor 4 Attach eccentric to new motor loosely 5 Carefully by hand turn motor shaft to top posi tion 6 Position eccentric on the motor spindle so that it is shifted one lock in position counterclockwise a Screw eccentric firmly in place and then fasten motor holder See Figure 3 24 7 Install motor and calibration bracket During installation ensure there is sufficient play be tween the eccent...

Page 38: ... cable remains disconnected 3 Attachvoltmeter DCrange topin2connector located at the top left corner of the Position Sensor assembly 4 Turn on the balance Settingverticalstop 1 Notedown1stvoltageassoonasthebalance has been switched on here the lever is at the bottom of the vertical stop 2 Determine2ndvoltagevaluebycarefullyrais ing lever with thumb and forefinger until it is at the top of the vert...

Page 39: ... Circuit Board PCB See Figure 5 2 for steps 1 through 4 1 With the balance turned OFF and unplugged open the Draft Shield door and remove the Pan 5 2 Remove Cover Plate 6 3 Inside of the Draft shield remove two Screws 2 and Lockswitch Cover Seal 1 4 Carefully lift the Draft Shield from the balance Base and set aside See Figure 5 3 for remaining steps 5 Remove two Screws 3 which secure Shield 4 in ...

Page 40: ... with the Load Cell If internal calibration option is installed connect cable to J4 14 Reinstall the PC Board and secure with two screws 3 15 Install the Hex Screws 14 and Washers 25 at the rear of the balance which secure the connectors on the PC Board 11 16 Install the Shield 4 back on the balance and secure with two Screws 3 Figure 5 3 17 Install the Draft Shield and secure with two Screws 2 ma...

Page 41: ... the Sensor PC Board Assembly Bracket 6 Proceed to paragraph 3 1 2 Load Cell Replacement and install the Load Cell back in to the balance Perform the Up Down Adjustment paragraph 3 1 3 or 3 1 4 3 2 3 Precision Top Loader Balances Main Printed Circuit Board PCB The circuitry used on the Main PCB is very complex Troubleshooting the Main PCB requires an Oscilloscope DVM hand tools and the services of...

Page 42: ...he defective Main PC Board to the replacement U5 EEPROM U10 IC U11 PSD 14 Install a replacement PC Board 15 Secure the PC Board 11 to the Base 18 with the two Screws 3 16 Connect the two cable connectors from the Load Cell 9 to the Main PC Board edge connectors J2 J6 and the Sensor Cable The Sensor Board Cable is located at the rear of the balance and may interfere with the operation of the balanc...

Page 43: ... the Power Supply PCB is being replaced replace the following components IC8 EPROM IC3 EEPROM IC12 IC NOTE When replacing the PC boards you will notice two grooves in the Base 19 The PC boards must be properly seated in these grooves when being replaced 9 Connect Connector PCB Cable 10 located in the Base 19 to the Power Supply PCB 7 10 Facing the front of the balance insert the Power Supply PCB 7...

Page 44: ...crews 15 which secures the Connector Plate 13 to the Connector PCB 14 10 Position the Connector Plate 13 over the holes on the side of the balance and install the two screws 12 11 Turn the balance in it s proper operating position and install the pan 1 12 Apply power to the balance 3 2 6 Removing the Display Module on Explorer Precision Top Loader Balances SeeFigure3 26 1 Remove power from the bal...

Page 45: ...ce with bottom facing you 3 Remove two screws from underneath the display 4 Underneath the front of the balance press the two tabs 1 towards the rear of the balance this will release the display 5 Carefully lift the display 2 up from the balance and swing towards the rear You will notice a grounding strap which is screwed into the base of the balance 6 Remove screw 3 and flat washer 4 from the gro...

Page 46: ...le from the Display PCB Assembly Connector 4 Press the two plastic Clips which hold the Display PCB Assembly in place outward to release the Display PCB Assembly and remove the PCB Assembly 5 Position the replacement Display PCB Assembly in place make sure the Membrane Switch Ribbon Cable passes through the hole on the Display PCB Assembly then press the Display PCB Assembly in place The Clips sho...

Page 47: ...r View of the Display PCB Assembly 3 2 9 Membrane Switch Replacement 1 Follow the procedure in paragraph 3 2 6 or 3 2 7 and remove the display module from the balance 2 Remove the membrane switch ribbon cable from the PC Board see Figure 3 28 3 On the front of the display carefully remove the existing membrane switch from the display panel Lift the membrane switch off starting at onecorner 4 Remov...

Page 48: ...rane switchdowntomake sure it is securly fastened 10 Replace the membrane switch ribbon cable see Figure 3 28 3 2 10 Replacing the Display 1 Secure the ground strap using the hardware previously removed 2 Plug the cable into the connector 5 on the PC board of the Voyager Display module See Figures 3 26 or 3 27 4 Carefully position the display flush with the top of the balance and press into positi...

Page 49: ...isplay 2 up from the balance and swing towards the rear You will notice a grounding strap which is screwed into the base of the balance 4 Remove screw 3 and flat washer 4 from the grounding strap 5 Carefully unplug the Main PCB Assembly Ribbon Cable 5 from the connector on the Display PCB Assembly of the display module CAUTION Be careful not to pull the RIBBON cable out of the connector on the mai...

Page 50: ...ment If the Bulb is not going to be replaced continue with this procedure 7 Assembly both boards together using the four Screws previously removed and reconnect the Bulb Connector 8 Place the PC boards into position over the four plastic guide posts which are slotted 9 Screw the four 4 40 x 3 16 Mounting Screws into the raised guides and secure both boards 10 Grasp the loose end of the Membrane Sw...

Page 51: ...CD Assembly over and pushing the on center portion of the Fasteners Turn the LCD Assembly back over and remove both pieces of the Fastener 4 Remove the Bracket from the LCD Assembly 5 Slide the Diffusion Panel out from the LCD Assembly 6 The Bulb has two End Caps slide both End Caps off of the Bulb See Figure 3 32 7 Using a low wattage soldering iron unsolder wire at each end of the Bulb 8 Slide t...

Page 52: ...3 32 CHAPTER 3 REPAIR PROCEDURES Figure 3 32 LCD Assembly Bulb Replacement BULB END CAP DIFFUSER PANEL BRACKET LCD ASSEMBLY PLASTIC PUSH IN FASTENER BULB WIRE ...

Page 53: ...l segments are enabled and displayed breifly then the model number of the balance followed by a software revision number This is a segment display test Figure 4 1 is a full display test Stable Mode Units Setup Custom Use keys to change B G NET P T Center of Zero press O T PG N lb ozcti mg press Enter kgdwt Change Figure 4 1 Segment Display When the balance is first turned ON and LFT has been previ...

Page 54: ...urn to 0g Record the reading 3 Repeat steps 1 and 2 ten more times Subtract the lowest from the highest reading to determine the differ ence Maximum allowable difference is as listed in Table 4 1 4 If the balance does not meet specifications refer to Table 2 1 to determine the problem 4 2 2 Off Center Load Test The Off Center Load Test is used to determine whether displayed weight values will be a...

Page 55: ...ensor Board which should also be disconnected from the PC Board not shown on Figure 5 3 The Load Cell 9 should now be exposed for adjustments 11 Reinstall the Pan 5 Figure 5 2 into the exposed Load Cell NOTE Do not attempt these adjustments on the balance unless the balance is free from drafts and is level The balance is very sensitive and adjustments will be affected 12 Plug the power cord into t...

Page 56: ...which secure the connectors on the PC Board 11 21 Install the Shield 4 back on the balance and secure with two Screws 3 Figure 5 3 22 Install the Draft Shield and secure with two Screws 2 making sure Lockswitch Cover Seal 3 Figure 5 2 is in place 23 Replace the Cover Plate 6 and Pan 5 inside of the Draft Shield Figure 5 2 NOTE If the Off Center Load Adjustment cannot be completed refer to the Prec...

Page 57: ...he two Hex Screws 1 from the Subplatform 2 7 Remove the Subplatform 2 8 Remove two Screws 3 which secure Shield 4 in place 9 Remove Shield 4 from the balance 10 Remove two Screws 3 from the PC Board 11 11 Remove the Hex Screws 14 and Washers 25 at the rear of the balance which secure the connectors on the PC Board 11 12 Disconnect the two cable connectors from the Load Cell going to J2 and J6 on t...

Page 58: ...is within tolerance as per table 4 1 6 Turn the balance OFF and remove power 7 Remove the Pan and Pan Support 2 8 Remove cable extenders connect the two cable connectors from the Load Cell 9 to the Main PC Board edge connectors J2 J6 and the Sensor Cable The Sensor Board Cable is lo cated at the rear of the balance and may interfere with the operation of the balance if it is not positioned away fr...

Page 59: ...essure as you pull the file towards you CAUTION CAUTION CAUTION CAUTION CAUTION Do not attempt to adjust if more than 5 counts out If more than 5 counts return to factory for repair File only in positions shown in Figure 4 6 On completion of the adjustments clean filing sites by removing residue with adhesive tape See Figure 5 6 for following steps 1 With power removed temporarily install the four...

Page 60: ...50g 100g 200g 40g 40g 150g 400g 400g 100g 600g 2000g 4000g 4000g 500g 4000g 6000g 8000g A 1g calibration mass is recommended for the reference mass All masses are nominal values HOWEVER BE CERTAIN TO USE THE SAME REFERENCE MASS THROUGHOUT THE PROCEDURE 1 Perform a linearity calibration see the calibration section of the instruction manual ASTM Class 1 Masses must be used for the calibration only T...

Page 61: ... set in the balance 1 Connect the balance to a computer that can run Hyperterminal or a similiar terminal program Using either the AS017 09 or AS017 02 cable Make sure the end of the cable marked balance is connected to the balance 2 Makesurethecommunicationparameters Baud DataBits parity stopbits arematched refertotheinstruction manual 3 Press the PRINT button on the balance 4 The terminal progra...

Page 62: ...4 10 CHAPTER 4 TESTING ...

Page 63: ...ked by Ohaus and can be ordered When a key number is enclosed by a four sided box it indicates that this part is NOT stocked by Ohaus and cannot be ordered The parts are shown for clarity only NOTE Inallcaseswhereapartisreplaced thebalancemustbethoroughlycheckedafterthereplacementismade The balance MUST meet the parameters of all applicable specifications in this manual If further technical inform...

Page 64: ...5 2 CHAPTER 5 DRAWINGS AND PARTS LISTS Figure5 1 OverallExplodedViewofPrecisionTopLoaderBalance O T O T 3 8 7 6 1 5 1 2 10 9 11 See Figure 5 2 NOTE Boxed items are not available for sale ...

Page 65: ...plorer Pro 6 11136113 Cover Top Loader Explorer Voyager Explorer Pro 9 490202 010 Power Adapter 100V 120V Explorer Voyager Explorer Pro 10 490203 010 Power Adapter 220V 240V Explorer Voyager Explorer Pro Note Requires Line Cord 11 76448 00 Line Cord UK Style Plug Explorer Voyager Explorer Pro 11 76199 01 Line Cord Australian Style Plug Explorer Voyager Explorer Pro 11 76198 00 Power Cord 220V E Eu...

Page 66: ...5 4 CHAPTER 5 DRAWINGS AND PARTS LISTS Figure5 2 OverallExplodedViewofAnalyticalBalance 1 5 6 8 O T O T 9 3 4 10 13 11 18 14 16 12 17 15 7 2 NOTE Boxed items are not available for sale ...

Page 67: ...108705 Window Front Explorer Voyager 11 11136765 Draft Shield Column Assembly Right Explorer Voyager Explorer Pro 12 11136764 Draft Shield Column Assembly Left Explorer Voyager Explorer Pro 13 11136701 Top Door Assembly Explorer Pro 14 11136703 Left Door Assembly Explorer Pro 15 11136702 Right Door Assembly Explorer Pro 16 11103535 Window Front Explorer Pro 17 11136360 Plate Draft Shield Explorer ...

Page 68: ...f Precision Top Loader Base Assembly 1 23 3 2 4 26 5 24 23 TO J2 TO J6 3 9 11 J7 J5 J6 J3 J4 J8 J2 J1 SWITCH POSITION TO J6 TO J2 CABLE TO DISPLAY MODULE TO J6 TO J4 TO J3 7 10 8 13 9 17 16 20 21 22 24 23 19 18 15 25 14 12 NOTE Boxed items are not available for sale ...

Page 69: ... 500g 410g 100g Explorer Voyager ExplorerPro 13 400103 010 Calibration Weight 62g 110g 200g 210g 210g 100g Explorer Voyager ExplorerPro 14 76580 21 Standoff Explorer Voyager Explorer Pro 16 400102 010 Weight Arm Explorer Voyager 18 11108101 Base Machined Explorer Voyager Explorer Pro 18 11136101 Base Machined Analytical Explorer Voyager 19 11108104 Foot Explorer Voyager Explorer Pro 20 00215053 Le...

Page 70: ...5 8 CHAPTER 5 DRAWINGS AND PARTS LISTS Figure 5 4 Exploded View of Analytical Load Cell 51D 51C 51E Lever Ratio Beam 51F Gold Wires NOTE Boxed items are not available for sale ...

Page 71: ...12106733 Guide Assembly Bottom Explorer Voyager 51E 12106731 Lever Ratio Beam with coil Older Explorer Voyager Analytical 51F 12106749 Contact Strips Kit of 10 Explorer Voyager Analytical 55 12106750 Ratio Beam Flexure Explorer Voyager Kit of 6 NOTES 1 In all cases where a part is replaced the balance shall be thoroughly checked after the replacement is made The balance must meet the parameters of...

Page 72: ...5 10 CHAPTER 5 DRAWINGS AND PARTS LISTS PR Zelle Explo Figure 5 5 Exploded View of Monoblock Load Cell for Precision Top Loader 4 1 500 3 2 ...

Page 73: ...orer Voyager Explorer Pro Hi Capacity 3 00225615 Board Load Cell Monoblock Explorer Voyager Explorer Pro Hi Capacity 4 81951 Reference Resistor 1 5k Explorer Voyager Explorer Pro 4 81881 Reference Resistor 760 ohms Explorer Voyager Explorer Pro NOTES 1 In all cases where a part is replaced the balance shall be thoroughly checked after the replacement is made The balance must meet the parameters of...

Page 74: ... CHAPTER 5 DRAWINGS AND PARTS LISTS Figure 5 6 Exploded View of High Capacity Top Loader Balance Sheet 1 of 2 28 30 13 1 19 27 10 12 15 31 36 12 16 39 14 29 12 3 NOTE Boxed items are not available for sale ...

Page 75: ...splay Cable Explorer Voyager High Capacity 19 00239026 Base Approved High Capacity 27 00239041 Level Support High Capacity 28 00215053 Level High Capacity 29 00230163 Security Screw High Capacity 30 11107002 Foot Set of 4 High Capacity 39 21202463 Display Lower Housing Explorer Voyager High Capacity NOTES 1 In all cases where a part is replaced the balance shall be thoroughly checked after the rep...

Page 76: ...AWINGS AND PARTS LISTS Figure 5 6 Exploded View of High Capacity Top Loader Balance Sheet 2 of 2 3 31 18 31 24 23 25 9 8 31 12 26 7 34 31 35 11 32 6 20 22 33 5 31 17 2 4 37 38 NOTE Boxed items are not available for sale ...

Page 77: ...248 Cable Cell 8 Position High Capacity 11 21202417 Cable Main PCB to Power Supply PCB High Capacity 18 00239108 Overload Protection High Capacity 26 00239039 CableGuide HighCapacity 33 00239035 Plate Protective High Capacity 34 00239038 Plate Insulating High Capacity 35 00239034 Plate Shielding High Capacity NOTES 1 In all cases where a part is replaced the balance shall be thoroughly checked aft...

Page 78: ...5 16 CHAPTER 5 DRAWINGS AND PARTS LISTS Figure 5 7 Exploded View of Monoblock Load Cell for High Capacity Top Loader Balance 3 2 5 4 NOTE Boxed items are not available for sale ...

Page 79: ...ion Sensor PCB High Capacity 4 00217400 Force Coil Lever Assembly Monoblock Explorer Voyager 5 21100229 Servomotor HighCapacity NOTES 1 In all cases where a part is replaced the balance shall be thoroughly checked after the replacement is made The balance must meet the parameters of all applicable specifications in this manual 2 Ohaus replacement parts warranty only applies to parts purchased from...

Page 80: ...5 18 CHAPTER 5 DRAWINGS AND PARTS LISTS Figure5 8 ExplodedViewofExplorerDisplay 1 2 3 O T O T 4 ...

Page 81: ...ed Explorer Voyager Explorer Pro High Capacity 3 11108413 Display PCB Assembly Explorer 4 11108525 Display Module complete Explorer NOTES 1 In all cases where a part is replaced the balance shall be thoroughly checked after the replacement is made The balance must meet the parameters of all applicable specifications in this manual 2 Ohaus replacement parts warranty only applies to parts purchased ...

Page 82: ...5 20 CHAPTER 5 DRAWINGS AND PARTS LISTS 1 2 3 O T O T Figure 5 9 Exploded View of Explorer High Capacity Display ...

Page 83: ...h Capacity 2 11136112 Cover Display Coated Explorer Voyager High Capacity 3 450111 010 Display Assembly Complete Explorer High Capacity NOTES 1 In all cases where a part is replaced the balance shall be thoroughly checked after the replacement is made The balance must meet the parameters of all applicable specifications in this manual 2 Ohaus replacement parts warranty only applies to parts purcha...

Page 84: ...5 22 CHAPTER 5 DRAWINGS AND PARTS LISTS Figure 5 10 Exploded View of Explorer Pro Voyager Display O T O T 3 10 1 11 ...

Page 85: ...Voyager 80850042 In use cover Explorer Explorer Pro Voyager Not shown 11 11108407 LCD Display PCB Bottom Explorer pro Voyager Voyager Pro no PSD or software 11 11136713 LCD Display PCB Bottom Explorer Pro w PSD 11 11136714 LCD Display PCB Bottom Voyager Pro w PSD NOTES 1 In all cases where a part is replaced the balance shall be thoroughly checked after the replacement is made The balance must mee...

Page 86: ...5 24 CHAPTER 5 DRAWINGS AND PARTS LISTS Figure 5 11 Exploded View of Voyager Explorer Pro High Capacity Display O T O T 3 10 1 11 ...

Page 87: ... Top Explorer Pro Voyager High Capacity 10 11108417 Bulb Replacement Explorer Pro Voyager and High capacity 11 11108483 LCD Display PCB Bottom Voyager High Capacity no PSD or software 11 11136716 LCD Display PCB Bottom Explorer Pro High Capacity w PSD NOTES 1 In all cases where a part is replaced the balance shall be thoroughly checked after the replacement is made The balance must meet the parame...

Page 88: ...5 26 CHAPTER 5 DRAWINGS AND PARTS LISTS ...

Page 89: ...e EP Loader software can not be used to restore the personality data in an Explorer that has the internal calibration option A 3 Installing EP Loader Software 1 Insert the EP Loader CD into the CD ROM 2 Run the setup executable found on the EP Loader CD to start the installation wizard 3 Follow the instructions in the installation wizard 4 If the CD is not available the software can be downloaded ...

Page 90: ...APPENDIX A EXPLORER EP LOADER A 2 A 4 Run EP Loader Software 1 Click on EP Loader icon located in Start Programs EP Loader 2 The following screen will be displayed ...

Page 91: ... Install the link by pushing down on the top and then rotating it 90 to lock it in position b If a manufacturing link is not available remove the RF shield and locate the hole through the printed circuit board that was under the manufacturing link access hole Short the two pads just to the front of this hole 8 Apply power to the balance 9 The balance will come on by itself and display MFG before t...

Page 92: ...2 In the same order as listed on the label input the Personality Data Label information into the Personality Data grid of the EP Loader After entering the data in Figure A 2 the loader willlook like the picture below See next page for display 610 x 1 mg 00000768C1A2 04 08 2003 83C1 03E4 F92F 1C52 2990 070C 42CF 17E7 CF8F 8E5F AB2F E3AD B70F 0F3B 74D3 4FB4 01B0 9A06 B92F 1C46 6957 0F38 475A 4C5F CB...

Page 93: ...ont 3 Confirm that the Balance Personality Data from the label matches the data that was inputted into the Personality Data section of the EP Loader If not edit the data If only the personality data is to be loaded uncheck the TC Data box in the Data Type box see below ...

Page 94: ... 1 a There are 2 major styles of label currently in use please refer to Figure A 3 2 Identify the values labeled in the diagram as A to J If the balance does not have internal calibration there will only be values A to G Then input into the TC Data location of the EP Loader accordingly The Loader will look like the picture below Figure A 3 TC Data ...

Page 95: ...he first entry of the AutoCal TC data H is entered the main screen will change See below The added grid is for loading the AutoCal Data in Explorer Pro balances It is not used for Explorer balances 3 Confirm that the TC Data from the label was correctly inputted into the TC Data of the EP Loader m ...

Page 96: ...ity Data and TC Data should be saved at this time as a complete file press Ctrl S on the keyboard or select File Save in the menu of the EP Loader 2 For a new Data file created a Save As pop up screen will appear to allow the Data file to be saved under the desired filename 3 To save an existing Data file under a different filename press Ctrl A on the keyboard or select File Save As in the menu of...

Page 97: ...fy the data Explorer display B 2 Installing EP Loader Software 1 Insert the EP Loader CD into the CD ROM 2 Run the setup executable found on the EP Loader CD to start the installation wizard 3 Follow the instructions in the installation wizard 4 If the CD is not available the software can be downloaded at the following URL HTTP fileshare ohaus com docushare a Click on Login b Login ServiceA Passwo...

Page 98: ...APPENDIX B EXPLORER PRO EP LOADER B 2 B 3 Run EP Loader Software 1 Click on EP Loader icon located in Start Programs EP Loader 2 The following screen will be displayed ...

Page 99: ...ot short to the balance casing 4 Remove the 2 screws securing the draft shield or top balance cover in place 5 Remove the plastic pan support clips if fitted 6 Remove the draft shield or top balance cover 7 Install the manufacturing link in the position shown in Figure B 1 a Install the link by pushing down on the top and then rotating it 90 to lock it in position b If a manufacturing link is not ...

Page 100: ...mmunication parameters of the EP Loader to match the balance then single click the Comm Test button A pop up screen will be displayed to indicate that the communication has failed or passed B 6 Temperature Compensation TC Data Entry 1 Locate the TC Data Label on the balance It will be under the display module Refer to Figure B 2 Figure B 2 TC Data 2 Identify the values labeled in the diagram as A ...

Page 101: ...RER PRO EP LOADER B 5 B 6 Temperature Compensation TC Data Entry Cont a When the first entry of the AutoCal TC data H is entered the main screen will change See next page The added grid is for loading the AutoCal data ...

Page 102: ...APPENDIX B EXPLORER PRO EP LOADER B 6 B 6 Temperature Compensation TC Data Entry Cont 1 Confirm that the TC Data from the label was correctly inputted into the TC Data of the EP Loader ...

Page 103: ...ta grid of the EP Loader If required also load the AutoCal data into the AutoCal grid of the loader After entering the data in Figures B 3 and B 4 the loader will look like the picture on the next page Figure B 3 Personality Data 610 x 1 mg 00000768C1A2 04 08 2003 83C1 03E4 F92F 1C52 2990 070C 42CF 17E7 CF8F 8E5F AB2F E3AD B70F 0F3B 74D3 4FB4 01B0 9A06 B92F 1C46 6957 0F38 475A 4C5F CB83 8C1A F8DB ...

Page 104: ...PRO EP LOADER B 8 B 7 Personality Data Label Entry Cont 4 Confirm that the Balance Personality Data from the label matches the data that was inputted into the Personality Data section of the EP Loader If not edit the data ...

Page 105: ...ta 1 The Personality Data and TC Data should be saved at this time as a complete file press Ctrl S on the keyboard or select File Save in the menu of the EP Loader 2 For a new Data file created a Save As pop up screen will appear to allow the Data file to be saved under the desired filename 3 To save an existing Data file under a different filename press Ctrl A on the keyboard or select File Save ...

Page 106: ...APPENDIX B EXPLORER PRO EP LOADER B 10 ...

Page 107: ...ing link access hole Short the two pads just to the front of this hole 8 Insure that the pan pan support and any hardware that makes up the dead load is on the balance The turn on zero will be written to memory during the calibration 9 Apply power to the balance The balance will come on by itself and display MFG before the normal turn on cycle This indicates the balance is in manufacturing mode C ...

Page 108: ...ow The balance will display MFgWt 6 Press and release Enter Print The balance will display INCAL The balance may also display Clr Pan briefly If this happens clear the pan or just press and release Enter Print if the pan is clear 7 You will hear the calibration drive motor turning The balance may go through a few repeat cycles This is normal if the environment is unstable You may see UNSTBLE this ...

Page 109: ... chip 9 Install the chip into the new bottom board 10 If necessary gently break away the excess pieces of the circuit board so that the board is the same shape and size as the old board and looks like the photo below 11 Short the two pins shown below 12 Remove the paper tab from between the battery and the positive terminal 13 Reassemble the complete display assembly 14 Reinstall the display assem...

Page 110: ... The settings while the service pins are shorted are 9600 baud Parity None Data Bits 8 Stop Bits 1 Handshake None Send the balance a V command to test communications The balance will respond with the software version 8 Start the Flash Programmer from your programs menu Note the communication settings and if necessary change to match the communications port you are using You should not have You sho...

Page 111: ...ly power to the balance The balance will then display Verify Flash Bank Checksum across the top of the display The following lines will show each bank followed by OK At the bottom of the display it will show KEY This allows you to test the keys individually The display will be as shown in the table below Explorer Models On Off Menu Print Mode O T Up ArrowDown Arrow Right Arrow Left Arrow Enter Voy...

Page 112: ...APPENDIX D REPLACING BOTTOM DISPLAY BOARD D 4 ...

Page 113: ......

Page 114: ...PN 80250985 SERVICE MANUAL EXPLORER EXPLORER PRO AND VOYAGER BALANCES 80250985 ...

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