Manual De Servicio Balanza De Humedad Mb45 Ohaus 482h3m
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Ohaus Corporation 19A Chapin Road P.O. Box 2033, Pine Brook, NJ 07058-2033
MB45 MOISTURE ANALYZER SERVICE MANUAL
Ohaus Corporation 19A Chapin Road, P.O. Box 2033, Pine Brook, NJ 07058-2033 (973) 377-9000
SERVICE MANUAL
MB45 MOISTURE ANALYZER
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Ohaus Corporation 19A Chapin Road P.O. Box 2033 Pine Brook, NJ 07932-0900 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 2006 Ohaus Corporation, all rights reserved. ® ed trademark of Ohaus Corporation.
TABLE OF CONTENTS CHAPTER 1 INTRODUCTION Page 1.1 Introduction .......................................................................................... 1-1 1.2 Service Facilities .................................................................................... 1-1 1.3 Tools and Test Equipment Required ...................................................... 1-2 1.3.1 Special Tools .................................................................................. 1-2 1.3.2 Tools and Supplies ........................................................................ 1-2 1.4 Test Mass Required ................................................................................ 1-2 1.5 Specifications ......................................................................................... 1-2 1.5.1 issable Ambient Conditions ..................................................... 1-2 CHAPTER 2.1 2.2 2.3
2 OPERATION Menu Structure .................................................................................. 2-1 Control Switch Functions................................................................... 2-2 Adjusting the Display Contrast and Brightness ................................. 2-3
CHAPTER 3 TROUBLESHOOTING 3.1 Troubleshooting ...................................................................................... 3-1 3.2 Troubleshooting Guide ........................................................................... 3-1 3.2.1 Diagnosis ........................................................................................ 3-1 CHAPTER 4 MAINTENANCE PROCEDURES 4.1 Preventive Maintenance ......................................................................... 4-1 4.1.1 Visual Inspection ............................................................................ 4-1 4.1.2 Preventive Maintenance Checklist.................................................. 4-1 4.2 Testing .......................................................................................... 4-2 4.2.1 Operational Test ............................................................................. 4-2 4.2.1.1 Display Test ...................................................................... 4-2 4.2.2 Weight Calibration .......................................................................... 4-3 4.2.3 Temperature Calibration ................................................................. 4-4 4.2.4 Performance Tests .......................................................................... 4-5 4.2.4.1 Precision Test ................................................................... 4-5 4.2.4.2 Off-Center Load Test ......................................................... 4-6 4.2.4.3 Centered Load Test ........................................................... 4-6 4.2.4.4 Visual Inspection ............................................................... 4-6 4.3 Repairing the Moisture Analyzer ............................................................. 4-6 4.3.1 Repairing the Drying Unit ............................................................... 4-7 4.3.1.1 Dismantling the Heating Module ....................................... 4-7 4.3.2 Replacing the Protective Glass and Reflector................................. 4-8 4.3.2.1 Replacing the Protective Glass and Reflector ................... 4-8 4.3.2.2 Installing Protective Glass and Reflector ........................... 4-8 4.3.3 Replacing the Halogen Lamp ......................................................... 4-8 4.3.3.1 Dismantle Halogen Lamp .................................................. 4-8 4.3.3.2 Installing the Halogen Lamp .............................................. 4-9 4.3.4 Replacing the Temperature Controller ............................................ 4-9 4.3.5 Replacing the Temperature Sensor .............................................. 4-10 i
TABLE OF CONTENTS (Cont.) CHAPTER 4 MAINTENANCE PROCEDURES (Cont.) 4.3.6 Installing the Heating Module ....................................................... 4-10 4.3.7 Removing Housing Top ................................................................ 4-11 4.3.8 Removing the Membrane Keypad ................................................ 4-13 4.3.9 Installing the Membrane Keypad .................................................. 4-13 4.3.10 Replacing the Display ................................................................... 4-14 4.3.11 Replacing the Fan ........................................................................ 4-14 4.3.12 Replacing the U Board ............................................................ 4-15 4.3.13 Replacing the Power Supply Board .............................................. 4-16 4.3.14 Replacing the Weighing Cell ........................................................ 4-17 4.3.15 Replacing the Housing Base ........................................................ 4-18 4.3.16 Installing the Housing Top .............................................................. 4-19 4.4 Resetting the Thermal Overload Device ................................................ 4-20 4.5 Final Work Steps ................................................................................... 4-21 CHAPTER 5 DRAWINGS AND PARTS LISTS 5.1 Drawings and Parts Lists ........................................................................ 5-1 5.1.1 Top Housing ................................................................................... 5-2 5.1.2 Bottom Housing .............................................................................. 5-4 5.1.3 Dryer Unit ........................................................................................ 5-7 APPENDIX A SOFTWARE SERVICE TOOL INSTRUCTIONS A.1 Software Service Tool Instructions ...................................................... A-1 A.2 Requirements ...................................................................................... A-1 A.3 Instructions and Notes ......................................................................... A-1 A.4 Error Messages ................................................................................... A-4
ii
TABLE OF CONTENTS (Cont.) LIST OF TABLES TABLE NO. 1-1 2-1 3-1 4-1 5-1 5-2 5-3
TITLE
PAGE NO.
Specifications ................................................................................. 1-2 Menu structure ................................................................................ 2-1 Diagnostic Guide ............................................................................ 3-2 Types of Performance Tests ........................................................... 4-5 Spare Parts List Top Housing ......................................................... 5-3 Spare Parts List Bottom Housing .................................................... 5-5 Spare Parts List Dryer Unit ............................................................. 5-7 LIST OF ILLUSTRATIONS
FIGURE NO.
TITLE
PAGE NO.
4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22 4-23 4-24 4-25 4-26
Access for Cleaning MB45 Moisture Analyzer ................................ 4-1 Display Test .................................................................................... 4-2 Dismantling the Heating Module ..................................................... 4-7 Removing the Heating Module ....................................................... 4-7 Replacing Protective Glass ............................................................ 4-8 Replacing Halogen Lamp ............................................................... 4-8 Installing the Halogen lamp ............................................................ 4-9 Replacing Temperature Controller.................................................. 4-9 Replacing Temperature Sensor .................................................... 4-10 Installing Heat module .................................................................. 4-10 Replacing Cover ........................................................................... 4-11 Remove Housing .......................................................................... 4-11 Remove Cable from Display ......................................................... 4-12 Remove Connectors ..................................................................... 4-12 Remove Membrane Keypad ......................................................... 4-13 Install Membrane Keypad ............................................................. 4-13 Replacing Display ........................................................................ 4-14 Replacing Fan .............................................................................. 4-14 Replacing U Board .................................................................. 4-15 Replacing Power Supply Board.................................................... 4-16 Replacing Weighing Cell .............................................................. 4-17 Replace Housing Base ................................................................. 4-18 Install Housing Top ....................................................................... 4-19 Plug in Cables .............................................................................. 4-19 Housing Top Reassembly .............................................................. 4-20 Resetting the Thermal Overload Device ........................................ 4-20
5-1 5-2 5-3
Top housing .................................................................................... 5-2 Bottom Housing .............................................................................. 5-4 Dryer Unit ........................................................................................ 5-6 iii
iv
CHAPTER 1 INTRODUCTION 1.1 INTRODUCTION This service manual contains the information needed to perform routine maintenance and service on the Ohaus MB45 Moisture Analyzer. The contents of this manual is contained in five chapters.
Chapter 1 Introduction - Contains information regarding service facilities, tools and test equipment, measuring masses, and specifications.
Chapter 2 Operation - Contains information on the control functions of the Moisture Analyzer. Chapter 3 Troubleshooting - Contains a diagnosis/diagnostics chart and error code table. Chapter 4 Maintenance Procedures - Contains preventive maintenance procedures, performance tests and adjustments, disassembly/replacement procedures, and calibration procedures. Chapter 5 Drawings and Parts Lists - Contains exploded views of all assemblies identifying serviceable components with parts lists. Before servicing the Moisture Analyzer, you should be familiar with the Instruction Manual which is packed with every unit.
1.2 SERVICE FACILITIES To service the Ohaus MB45 Moisture Analyzer, the service area should meet the following requirements: DO NOT SERVICE the Moisture Analyzer: • Next to open windows or doors causing drafts or rapid temperature changes. • Near air conditioning or heat vents. • Near vibrating, rotating or reciprocating equipment. • Near magnetic fields or equipment that generates magnetic fields. • On an unlevel work surface. • Allow sufficient space around the instrument for ease of operation and keep away from radiating heat sources.
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1-1
CHAPTER 1 INTRODUCTION 1.3 TOOLS AND TEST EQUIPMENT REQUIRED This section contains information on tools and supplies required to properly service the MB45 Moisture Analyzer. These items are listed as follows:
1.3.1 Special Tools None required.
1.3.2 Tools and Supplies 1.Digital Voltmeter (DVM) - Input impedance of at least 10 megohms in the 1 Volt dc position. 2.Standard electronics tool kit 3.Soldering iron (50 watt) and solder (rosin core solder, not acid core). 4.Solder remover. 5.Ohaus Temperture Calibration Kit P/N 11113857 6.Soft, lint-free cleaning cloth 7.Anti-static bags for PCBs 8.Anti-static wrist strap and mat
1.4 TEST MASS REQUIRED It is recommended that a ASTM Class 1 Tolerance mass be used. The mass required is 20 grams.
1.5 SPECIFICATIONS Complete specificatons for the MB45 Moisture Analyzer are listed in Table 1-1. When an MB45 has been serviced, it must meet the specifications listed in Table 1-1. Before servicing the Moisture Analyzer, determine what specifications are not met.
TABLE 1-1. SPECIFICATIONS Capacity Readability Heat Source Calibration Dimensions (DxWxH) (in/cm) Operating Temperature Range Power Requirements Weight (lb/kg) Shipping Weight (lb/kg)
45g 0.001g, .01% Halogen bulb - 120 V or 240 V External calibration mass-20g 14 x 7.5 x 7/ 35.5 x 19 x 17.8 10°C to 40°C 100V ac -127V ac or 230V ac - 240V ac, 50/60Hz 9.8 / 4.5 14.1 / 6.4
1.5.1 issible Ambient Conditions Temperature range: Atmospheric humidity: Voltage fluctuations: Installation category: Pollution degree: Power load: Current consumption: Power supply voltage: Power line fuse:
Use only in closed rooms 5 ºC to 40 ºC 80% rh @ to 30 ºC –15% +10% II 2 Max. 450 W during drying process 4 A or 2 A, according to the heating element 100 V – 120 V or 200 V – 240 V, 50/60 Hz (the voltage is given by the heating element) 1 piece, 5 x 20 mm, T6,3 H 250 V
1-2
CHAPTER 2 OPERATION 2.1 MENU STRUCTURE This chapter contains menu structure, control swich operation and display adjustments. For complete operation, refer to the Instruction manual supplied with the unit. The menu structure is illustrated in the table below.
TABLE 2-1. MENU STRUCTURE
TEST MENU
SETUP
Test Library
Setup
Edit Test Test Parameters 01 Test ID: Load Test Profile: Edit Test Standard Delete Test Fast 02 Ramp Load Test Step Edit Test Dry Temp: Delete Test Switch Off: • Timed- Switch Off • Manual-Use Start/Stop • AFREE - Wt loss/time • A90 - <1MG in 90 seconds 50 A60 - <1MG in 60 seconds Load Test A30 - <1MG in 30 seconds Edit Test Result: Delete Test % Moisture Custom Units Grams % Regain % Solids Custom Factor, Exponent, LSD Target Wt: Print Int: Off, 1, 3, 5, 10, 30 Sec 1, 2, 5 Min. Save Test:
Lockout Weight Calibration Temperature Calibration Language English, Deutsch, Espaniol, Francais, Italiano Beeper Low, High, Off Time-Date Format MM/DD/YR, DD/MM/YR Set Date Time format 12HR, 24HR Set Time AM, PM RS232 Baud Rate 1200, 2400, 4800, 9600, 19,200 Parity Odd, Even, None Data Bits 7, 8 Stop Bits 1, 2 Handshake None, XON-XOFF, RTS-CTS Print Print On/Off GLP On/Off Display Contrast Brightness Factory Reset
2-1
CHAPTER 2 OPERATION 2.2 CONTROL SWITCH FUNCTIONS
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Enter
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Function Turns ON/OFF display and fan. ON returns with last screen. (All modes)
2
Test Menu button
When pressed, selects Test Library screen.
3
Display button
When pressed, will return to the current test or cycles through several display screens (run mode).
4 5 5
Setup button
When pressed, brings up analyzer setup menu.
Start/Stop button
When pressed, either starts or stops drying process.
6
button
When pressed, travels up through menu options and selects alphanumeric characters.
7
button
When pressed, travels to the left through displays.
8
button
When pressed, travels to the right through displays.
9
button
When pressed, travels down through menu options and selects alphanumeric characters.
110
Enter/Print button
When pressed, accepts selection/input (select mode) or sends print command during a test (run mode).
11
Tare button
When pressed, performs a tare function. Pressing during a test has no effect.
12
Leveling feet
Used to level the Moisture Analyzer.
2-2
CHAPTER 2 OPERATION 2.3 ADJUSTING THE DISPLAY CONTRAST AND BRIGHTNESS Enter the ANALYZER SETUP menu, this menu permits adjusting the contrast and brightness levels on the display screen. To change the levels, proceed as follows:
ANALYZER SETUP LANGUAGE BEEPER TIME-DATE RS-232 PRINT DISPLAY
DISPLAY ADJUST CONTRAST:
60
BRIGHT:
10
Press the Setup button. Using the down arrow button, scroll to DISPLAY. Press the Enter button.
Adjusting contrast Using the up/down arrow buttons, adjust the screen contrast to the desired level. The numeric value (0 to 100) is for reference only. Press the right arrow button to advance to BRIGHT. Default = 40.
EXIT WITHOUT SAVING
DISPLAY ADJUST CONTRAST:
60
BRIGHT:
10
Adjusting brightness Using the up/down arrow buttons, adjust the screen brightness to the desired level. The numeric value (0 to 10) is for reference only. Press the Enter button. Default = 10.
EXIT WITHOUT SAVING
DISPLAY ADJUST CONTRAST:
60
BRIGHT:
10
Exit without saving If you do not wish to save settings, Use the right arrow button and scroll to EXIT WITHOUT SAVING and press the Enter button. The display returns to ANALYZER SETUP.
EXIT WITHOUT SAVING
2-3
CHAPTER 2 OPERATION
2-4
CHAPTER 3 TROUBLESHOOTING 3.1 TROUBLESHOOTING This section of the manual specifies problem areas of the MB45 Moisture Analyzer which can occur. Information is contained to isolate specific problems using the Troubleshooting Guide. Make certain that the work area is clean and use care when handling components of the Analyzer.
3.2 TROUBLESHOOTING GUIDE A Troubleshooting Guide is designed to help you locate the problem area quickly and easily. First locate the problem that you are observing. The probable causes are listed with the most common cause first. Before attempting to repair the Analyzer, read all chapters of this manual to familiarize yourself with the components and operation. Do not attempt repairs unless you fully understand the operation of the Analyzer.
3.2.1 Diagnosis 1.Isolate and identify the symptom. 2.Review the probable causes in the order that they appear. 3.See the appropriate section of the manual to correct the malfunction. 4.Repair or replace the defective section of the Moisture Analyzer. NOTE: If more than one symptom is observed, it is necessary to approach one area at a time, and also , that the symptoms may be interrelated. In the event that erratic or fluctuating weight readings are observed, it is necessary to isolate the problem to either the mechanical area or the electronic area of the Moisture Analyzer. If a problem arises that is not covered in this manual, :
Ohaus Corporation 19A Chapin Road P.O. Box 2033 Pine Brook, NJ 07058-2033 USA Tel: 973-377-9000 Fax: 973-944-7177
In the United States call toll free, 800-526-0659 between 8:00 a.m. and 6:00 p.m. EST.
3-1
CHAPTER 3 TROUBLESHOOTING 3.2 TROUBLESHOOTING GUIDE (Cont.)
TABLE 3-1. DIAGNOSTIC GUIDE SYMPTOM Moisture analyzer cannot be switched on. Moisture analyzer cannot be switched on green LED on power supply board does not light up.
Moisture analyzer cannot be switched on. Green LED on power supply board lights up.
PROBABLE CAUSE(S)
REMEDY
Power cord not plugged in or no power Check supply voltage. The power supply is designed for 100...240 VAC, but the drying unit only Defective main fuse. for 110 or 230VAC. Check whether the correct drying unit is installed. Check Defective power supply fuse. the fuses on the back of the instrument and the power supply board. Cable connections inside instrument not Plug in or replace cable. plugged in or defective. Defective U board.
Replace U board.
Moisture analyzer cannot be switched on green LED on power supply board does not light up.
Defective power supply fuse. Defective power supply board.
Replace power supply fuse on power supply board. Replace power supply board.
Some buttons do not respond.
Defective keypad wiring.
Replace membrane keypad.
Keypad does not function.
Keypad not plugged in
Check keypad.
Defective keypad wiring
Replace membrane keypad.
Portions of the display do not light up.
Defective display.
Replace display.
Halogen lamp does not switch on after "Start".
Thermal overload device has tripped.
Reset thermal overload device, see paragraph 4.4.
Defective temperature controller.
Replace if resistance after resetting is > 1 Ohm. Replace if resistance > 20 Ohms (check whether 100 or 230 VAC).
Defective halogen lamp.
Temperature sensor not plugged in or Plug in or replace sensor. defective. Defective power supply board.
Replace power supply board.
Defective U board.
Replace U board.
Halogen lamp switches off before end of test.
Incorrect Halogen bulb
Check voltage rating on bulb.
Temperature rises above 205 degrees C.
Defective temperature sensor. Defective power supply board. Defective U board.
Replace temperature sensor. Replace power supply board. Replace U board.
Unstable weight indication.
The air current which cools the weighing Clean the ventilation grill. cell is blocked.
3-2
CHAPTER 4 MAINTENANCE PROCEDURES 4.1 PREVENTIVE MAINTENANCE Ohaus MB45 Moisture Analyzers are precision instruments and should be carefully handled, stored in a clean dry area which is dust free, and cleaned periodically. It is recommended that when a Analyzer has had chemicals or liquids spilled on it, the Analyzer should be cleaned as soon as possible. Use warm water on a damp cloth to clean all exterior surfaces. Do not leave a mass on the sample pan when the Analyzer is not in use. When moving the unit from a storage area which is at a different temperature than the area where it is to be operated, allow sufficient time for the mechanism to temperature stabilize. This time can vary quite a bit depending upon the temperature differences. Allow one (1) hour for each 5 degrees Fahrenheit temperature change before using the Moisture Analyzer. Also, after turning the Analyzer ON, allow five minutes after temperature stabilization for the internal electronics to stabilize.
4.1.1 Visual Inspection When a Moisture Analyzer is first received for repairs, the unit should be checked visually for completeness. — Check on completeness in accordance with standard equipment. — Check on the condition of the following parts: • Housing • Keypad and display • Draft shield with heat shield, pan handler and pan • Dryer unit with protective glass, Halogen radiator, reflector • Fan grill (rear) • Leveling feet and level • Rating plate
4.1.2 Preventive Maintenance Checklist On a regular basis, the MB45 Moisture Analyzer should be inspected and checked as follows: 1.Remove power from the MB45.
2.Remove the Pan , Draftshield and Heatshield and inspect the interior and exterior of the Moisture Analyzer. 3.Clean the outside of the Moisture Analyzer using a damp cloth with water or a mild household detergent. 4. Remove any debris which may have accumulated under the pan or shields.
Glass Shield Pan Draft Shield Heat Shield
5.Inspect the protective glass shield and clean any spattered material which may have accumulated on the glass. 6.Inspect fan opening for excessive dust.
Figure 4-1. Access for Cleaning MB45 Moisture Analyzer. 4-1
CHAPTER 4 MAINTENANCE PROCEDURES 4.1.2 Preventive Maintenance Checklist (Cont.) CAUTION DO NOT USE CHEMICAL CLEANERS OR SOLVENTS OF ANY TYPE. SOME CLEANERS ARE ABRASIVE AND MAY AFFECT THE FINISH OF THE ANALYZER. 7.Check the Power Cord for broken or damaged insulation. 8.Make a visual inspection for faulty connectors, wiring, and loose hardware.
4.2 TESTING Before servicing the MB45 Moisture Analyzer, an operational test and various performance tests should be made to ascertain whether or not the unit meets specifications. Turn the Moisture Analyzer on and allow it warm up for at least one hour before performing these tests. Make sure the test area is free from drafts and the surface that the Moisture Analyzer rests on is level and vibration free. It is recommended that a ASTM Class 1 Tolerance mass be used for the performance tests and adjustments.
4.2.1 Operational Test 1.Locate a suitable power source for the Moisture Analyzer. Check the voltage rating of the Moisture Analyzer. 2.Plug the Power Cord into a suitable power source. NOTE: If possible, record original customer settings so that after repairs, the Moisture Analyzer can be returned in a satisfactory operational mode.
4.2.1.1 Display Test 1.Turn the Moisture Analyzer on, a MB45 Moisture Analyzer display with the Ohaus logo should appear followed by the software revision currently installed in the Moisture analyzer. After this display, a standard display appears. This is a display test. Figure 4-2 is a full display test. The software revision will only appear after plugging in the analyzer for the first time. Subsequent power on using the On/Off button will not display the software revision. 2.Press the TARE button. The display should indicate a zero weight.
®
Sr 1.06b TEST ID: TEMP/TIME: TARG. WGT:
-DEFAULT100C / 10:00 1 GRAMS
CLEAR PAN PRESS TARE
0.000 * GRAMS
Figure 4-2. Display Test. 4-2
CHAPTER 4 MAINTENANCE PROCEDURES 4.2.2 Weight Calibration The Moisture Analyzer can be span calibrated with an external mass of 20 grams. Calibration of the Moisture Analyzer balance is not absolutely necessary for a correct moisture determination as the measurement is relative. The balance determines the weight of the sample before and after drying and the moisture is calculated on the basis of the ratio between wet and dry weights. Nevertheless, you should calibrate the built-in balance under the following conditions: — If this is stipulated by your quality assurance system (GLP, GMP, ISO 9001). — If you suspect the analyzer has been abused. — Before and after all repairs. To calibrate the Analyzer, proceed as follows:
ANALYZER SETUP LOCK OUT WEIGHT CAL TEMP CAL LANGUAGE BEEPER TIME-DATE
Clear the pan handler, a sample pan should be in place, close the cover on the Moisture Analyzer. Press the Setup button. Using the arrow buttons, scroll to WEIGHT CAL. Press the Enter button. The display screen highlights the action you should take.
WEIGHT CAL PLACE 20G MASS
Place the required weight on the sample pan, close the cover. Follow the instructions on the display. The display indicates if the calibration was successful.
TO ABORT PRESS STRT/STP KEY
Press the Display button to return to display. To abort, press START/STOP button.
4-3
CHAPTER 4 MAINTENANCE PROCEDURES 4.2.3 Temperature Calibration You must have an Ohaus Temperature Calibration Kit, (Part Number 11113857) to perform this procedure. If the Moisture Analyzer has been recently used, allow at least 30 minutes before performing calibration.
ANALYZER SETUP LOCK OUT WEIGHT CAL TEMP CAL LANGUAGE BEEPER TIME-DATE
NOTE: The Temperature Calibration Kit is available as optional equipment. Press the Setup button. Using the arrow buttons, scroll to TEMP CAL. Press the Enter button. You are now prompted to remove the pan handler and pan . Replace the pan handler and place a temperature calibration unit on the pan handler.
TEMP CAL
NOTE: The unit will not calibrate with the pan in place.
REMOVE PAN HANDLER AND PAN ABORT CALIBRATION
Press the Enter button to initiate the temperature calibration process. Follow the screen prompts throughout the process.
TEMP CAL 100C CURRENT TEMP: TM TO CAL POINT:
--- C 15:00 MIN
The dryer unit is heated to a temperature of 100°C. You can observe the progress on the display as the dryer temperature and count down period are displayed. After 15 minutes, read the thermometer through the inspection window on the cover and enter this temperature. Using the up/down arrow buttons, adjust the display reading to agree with the thermometer. Use the left/right arrow buttons to highlight ACCEPT NEW CAL, then press the Enter button. You have 10 minutes to make this adjustment, otherwise the calibration is terminated.
ADJ CAL READING: 100 C ACCEPTS NEW CAL ABORT CALIBRATION
TEMP CAL 160C CURRENT TEMP: TM TO CAL POINT:
100 C 15:00 MIN
ADJ TO CAL READING: 160 C ACCEPTS NEW CAL ABORT CALIBRATION
This is a two point adjustment (100°C and 160°C). The dryer unit now heats to the second temperature (160°C). Adjustment of the temperature is defined by two points. Proceed exactly as you did for the first temperature. After you have set the display to agree with the thermometer, highlight ACCEPT NEW CAL, then press the Enter button. The display returns to ANALYZER SETUP.
WARNING: Be careful when removing the temperature calibration unit from the dryer unit as it can be very hot. Allow it to cool down by opening the cover before removing. Remove the calibration unit. Replace the pan and the pan handler in their proper positions.
4-4
CHAPTER 4 MAINTENANCE PROCEDURES 4.2.4 Performance Tests Accurate performance of the MB45 Moisture Analyzer is determined by a series of three performance tests. Precision, Off Center Load and Centered Load. The displayed readings are compared with the tolerances listed in Table 4-1. Tolerance values are expressed in grams. Before starting the performance tests, level the Moisture Analyzer.
TABLE 4-1. TYPES OF PERFORMANCE TESTS PERFORMANCE TEST
TOLERANCE
Precision (Standard Deviation)
0.0015g
Off Center Load
+0.004g
Centered Load
+0.004g
The following performance tests are used to evaluate the Moisture Analyzer operation before and after repairs. Each Moisture Analyzer tested must meet the requirements specified in each test as well as the specifications listed in Table 1-1. Before proceeding with the following tests, all the procedures starting with paragraph 4.2 must have been accomplished on the Moisture Analyzer first. Tolerance values are expressed in counts. A Moisture Analyzer which es each of these three tests meets the manufacturing specifications.
4.2.4.1 Precision Test Precision is a word used in balance specifications meaning the Standard Deviation of a set of similar weight readings. To determine whether an Analyzer meets the calculated Standard Deviation value in the Specification Table 1-1, perform the following test:
Test 1.Tare the Analyzer. The reading on the display should be 0.000g. 2.Place a 20g mass on the center of the sample pan. Observe and record the reading when the stable indicator come on. 3.Remove the mass. Reading should return to 0g +0.002g when the stable indicator is on. 4.Repeat this test for ten readings. If the standard deviation of the readings is less than 0.0015g, the Moisture Analyzer es the Precision Test. CAUTION: Remove the mass from the pan after testing.
Adjustment If the deviation for any set of readings (using the same mass placed on the center of the pan) is greater than 0.0015g, the Moisture Analyzer does not meet the Precision Test specification. Inspect and correct the following areas: 1.Check for mechanical obstructions. Any foreign object touching any part of the moving pan linkage assembly will cause a Moisture Analyzer to fail the Precision Test. Inspect and correct as necessary. 2.An error in the Off-Center Load Test can affect the results of the Precision Test. Inspect and correct if necessary. See Off-Center Load Test. 3.Foreign material or debris located in the balance between the pan and the base will cause the Moisture Analyzer to fail the test. 4.Environmental influences such as vibrations, drafts or a non-level surface can cause failures.
4-5
CHAPTER 4 MAINTENANCE PROCEDURES 4.2.4.2
Off-Center Load Test
The Off-Center Load Test is used to determine whether displayed weight values will be affected by moving the sample to different areas of the sample pan. (NOTE: Due to the use of relative weighing in moisture analysis, off center load performance is not critical.)
Test 1.Place a sample pan on the pan handler. 2.Place 1/2 of the Moisture Analyzer capacity (20 gramms) in the center of the sample pan. 3.Press the TARE button to return the reading to zero. 4.Move the mass halfway (between the center and the edge) to the front of the sample pan. Note any differences in the displayed weight reading. 5.Repeat this test for the back, left, and right positions. 6.Maximum allowable change in displayed weight readings is +0.004g for each of the four positions. If this reading is exceeded, it usually indicates a defective Weighing Cell.
4.2.4.3 Centered Load Test This test is used to determine the linearity of the unit throughout its operating range. NOTES: 1. Due to the use of relative weighing and limited use of the weighing range in moisture analysis, linearity performance is not critical. 2. The Moisture Analyzer must the Off-Center Load Test and Precision Test before the Centered Load Test may be performed.
Test 1.Place a 20g mass on the center of the sample pan and note the reading. 2.If the displayed weight is greater than 0.002g higher or lower than the value of the applied mass, and recalibrate the Moisture Analyzer. The Moisture Analyzer should now be calibrated in grams. 3.After completing the above adjustments, check the linearity at 10g and 20g. The displayed weight readings should be equal to the applied mass. Tolerance is +0.004g for each of the respective weight readings. If the displayed weight values are in excess of tolerance count, the Weighing Cell must be replaced.
4.3 REPAIRING THE MOISTURE ANALYZER Disconnect from power supply and allow heating module to cool ! Important: Electrostatic protection when servicing !
Electrostatic damage is difficult to detect, because the faults it causes are not clear cut. MOS switching transistors with electrostatic damage have substantially higher, thermically unstable leakage currents. As a result, the Moisture Analyzer balance drifts more and the display can fluctuate similar to when there is a draft. To avoid electrostatic damage during production, conducting floors, controlled air humidity, and EMC mats are used. When servicing is carried out it is therefore also advisable – as soon as the instrument is opened – to neutralize electrostatic charges. 4-6
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.1 Repairing the Drying Unit 4.3.1.1 Dismantling the Heating Module 1. Swivel drying unit upward. 2. Unscrew 4 screws (a). 3. Pull cover off toward back.
a
Figure 4-3. Dismantling the Heating Module.
4. Unscrew 2 screws (b).
b
5. Lift heating module out. 6. Disconnect heater cable at 2 connectors (c).
c
Figure 4-4. Removing the Heating Module. 4-7
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.2 Replacing the Protective Glass and Reflector
e
Swivel drying unit up and unscrew cover (d).
4.3.2.1 Removing Protective Glass and Reflector
f
1. Pull reflector (e) up and out. 2. Pull protective glass (f) up and out.
4.3.2.2 Installing Protective Glass and Reflector 1. Insert protective glass with opening pointing down. 2. Insert reflector. 3. Screw cover on (d).
d
Figure 4-5. Replacing Protective Glass. 4.3.3 Replacing the Halogen Lamp 4.3.3.1 Dismantle Halogen Lamp 1. Dismantle the heating module. 2. Dismantle protective glass and reflector. 3. Use both forefingers to spread the clamping springs to the left and right and at the same time use both thumbs to lift the Halogen lamp carefully upward out of the clamping springs (the two ends ot the Halogen lamp must not be bent toward or away from each other, otherwise, the glass tube will break).
Figure 4-6. Replacing Halogen Lamp. 4-8
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.3.2 Installing the Halogen Lamp a CAUTION: Finger oils can cause premature lamp failure. Only touch the black part of the Halogen lamp! If necessary, clean the lamp with a weak organic solvent.
b c
1. Hold the new Halogen lamp by the black ends and insert it into the two metal s (a) at the back. If the metal s have fallen out, replace them so that the wider part of the fork (b) is on top; the metal s must press the Halogen lamp gently against the protective glass (c). 2. Lay the flat,connector side of the Halogen lamp on the clamping springs at the front,use both thumbs to push it about 2 mm toward the back against the metal s and then down to engage in the clamping springs.
Figure 4-7. Installing the Halogen Lamp.
3. Reconnect the 2 connectors of the Halogen lamp. 4. Install the protective glass and reflector. 5. Install the heating module.
4.3.4 Replacing the Thermal Overload Device (Thermal cut-out switch) NOTE: Before replacing the the thermal overload device, it may have tripped and has to be reset. Refer to paragraph 4.4 to reset the thermal overload device.
d e
1. Dismantle the heating module. 2. Use flat-nosed pliers to pull off the two cable connectors. 3. Replace temperature controller (e). Do not forget the spacing washer on the heat-conducting plate (d)! Do not tighten the washer too tight (1.2 Nm). 4. Tighten nut with 1.2 Nm. If the temperature controller has responded,reset with finger (do not push spring under edge of base!).
4-9
Figure 4-8. Replacing Thermal Overload Device.
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.5 Replacing the Temperature Sensor 1. Dismantle heating module. 2. Pull off the connector (a). 3. Remove screw (b) and (c),lift temperature sensor out of its holder and replace minding to
c d
pull the sensor cable through the clamp (d) also see Figure 4-10.
b
a
4. Screw temperature sensor firmly back into place and push connector (a) on again. 5. Install heating module.
Figure 4-9. Replacing Temperature Sensor. 4.3.6 Installing the Heating Module 1. Reconnect the 2 connecting cables (f) and (g) of the heater. e
2. Insert the heating module into the frame and fasten with 2 screws (e). The bare connector (f) carries the 220 V power supply voltage and must therefore always be installed as shown. It must not lie outside the heating module like connector (g).
f
g
Figure 4-10. Installing Heat Module. 4-10
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.6 Installing the Heating Module (Cont.) 3. Replace cover and fasten with 4 screws (a). 4. Swivel drying unit closed.
a
Figure 4-11. Replacing Cover.
4.3.7 Removing Housing Top 1. Remove pan handler, pan , and draft shield. 2. Lift heat shield off. 3. Remove screw (a) and then lift the sample chamber, first at the front and then completely.
a
4. Remove the 4 screws (b) from the housing top.
b
Figure 4-12. Remove Housing. 4-11
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.7 Removing Housing Top (Cont.) 5. Lift the front of the housing top then,using a screwdriver, carefully unfasten the connector socket of the keyboard cable (b)and pull off the cable. Pull off the cable of the display (a).
a
b
Figure 4-13. Remove Cable from Display. 6. Lift the housing top until the level indicator (d)is free, then swivel it into the vertical position toward the back to rest against the open cover of the drying unit. 7. Pull off the connectors for the fan (a), temperature sensor (b), and Halogen lamp (c). 8. Put the housing top aside out of the way.
d
a b
c
Figure 4-14. Remove Connectors. 4-12
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.8 Removing the Membrane Keypad 1. Remove the housing top. 2. Release the faulty membrane keypad from the cable side (h). 3. Remove any traces of adhesive (if necessary,use pure benzene). WARNING Benzene is highly flammable, use only in small quantities.
h
Figure 4-15. Remove Membrane Keypad.
4.3.9 Installing the Membrane Keypad Avoid making finger marks and getting dust on the display and window of the membrane keypad! 1. Insert the cable of the new membrane keypad. 2. Pull the covering foil off the adhesive surface. 3. Insert the membrane keypad into the depression in the housing top, starting only with the front, right-hand corner and then with the right-hand edge. Then, roll it toward the left into the depression and press it down. 4. Install the housing top. (See 4.3.16)
Figure 4-16. Install Membrane Keypad.
4-13
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.10 Replacing the display 1. Remove housing top. 2. Unscrew display and remove. 3. Insert new display and fasten with screws. 4. Install housing top. (See 4.3.16)
Figure 4-17. Replacing Display. 4.3.11 Replacing the fan 1. Remove housing top. 2. Unscrew screening plate from housing top.
k
3. Slide cable (i) out through grommet (k), remove grommet (k) from screening plate together with fan connector. 4. Replace fan,taking care to install it in the direction indicated by the arrow printed on it (m).
m
p
5. Assemble the housing top: do not forget the spring (p)! (The pin triggers the safety switchoff if the housing top is opened during operation.)
i
6. Install housing top. (See 4.3.16) 7. Test safety switchoff for correct functioning: • Start drying so the the lamp is lit. • Open the cover of the MB45: the lamp should switch off immediately. If it does not, check whether the spring (p) is pressing the safety pin upward (q): q
Figure 4-18. Replacing Fan. 4-14
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.12 Replacing the U board 1. Remove housing top. 2. Remove screening plate (a). 3. Pull off the connector to the power supply (b), carefully unfasten the socket connector of the weighing cell cable (c), and pull the cable out. a 4. Unscrew the U board and remove. 5. Transfer the cell EEPROM (d) from the old U board, replacing the battery (e) with a new one if necessary (3 V, Lithium,e.g. CR 2032). 6. Install new U board.
b
d
e c
7. Install screening plate (a). 8. Re-insert cables (b)and (c) and fasten. 9. Install housing top. (See 4.3.16) 10. Perform weighing and temperature calibration. 11. After replacing the PC Board, refer to Appendix A and follow the instructions to configure the new PC Board.
Figure 4-19. Replacing U Board.
4-15
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.13 Replacing the power supply board 1. Remove housing top.
f
2. Remove the screw (f) at the back of the screening plate. 3. Pull off the 4 connectors for the U board (g), fan (i), temperature sensor (k) and lamp (m). 4. Remove screw to release ground protection cable (h). 5. Remove the 4 screws from the power supply board and the 2 screws (o) from the RS232 interface socket. Lift the power supply board at the front and remove it.
k i
g m
p
6. Install new power supply board: • First tighten the 2 screws (o) of the RS232 interface socket then the 4 screws with toothed washers of the power supply board. • Screw the eye of the ground protection cable and the toothed washer firmly under the head of screw (h).
h o
r
7. Screw in the back screw (f) of the screening plate. 8. Plug in the 4 connectors. 9. If necessary, replace the main fuse (r)T6.3 A/ 250 V or power supply (p) 500 mA/250 V. 10. Install the housing top. (See 4.3.16)
Figure 4-20. Replacing Power Supply Board.
4-16
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.14 Replacing the Weighing Cell 1. Remove housing top. 2. Remove screening plate (a)and seal (b). 3. Unfasten the socket connector (e) of the cell on the U board and pull out the cable. 4. Unscrew weighing cell (c) and remove. 5. Install new weighing cell in reverse order.
a b
6. Replace cell EEPROM (d). 7. Install screening plate. 8. Install housing top. (See 4.3.16) 9. Perform weight calibration.
d
c
e
Figure 4-21. Replacing Weighing Cell.
4-17
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.15 Replacing the Housing Base 1. Remove housing top. 2. Remove the following parts from the old housing base and install them on the new one:
h
• Leveling screws • U board (c). • Power supply board (d).
g e
• Weighing cell (e). • Level indicator (f) • Seals (g) • Screening plate (h) 3. Install housing top. (See 4.3.16)
d
f
c
Figure 4-22. Replace Housing Base.
4-18
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.16 Installing the Housing Top 1. Lay the housing top toward the back on the opened cover of the drying unit. 2. Insert connectors for fan (a), temperature sensor (b), and Halogen lamp (c). 3. LIft the housing top until it is above the level indicator (d), tilt it into the horizontal position, then over the level indicator and seal and lower it onto the housing base. CAUTION: that cables for fan (a), temperature sensor (b) and Halogen lamp (c) are clear from housing top when installing. Wires can be damaged if not positioned properly and can possibly cause damage to the Moisture Analyzer.
d
a
c
b
Figure 4-23. Install Housing Top.
4. Plug in the cables of the display and keyboard. Position the ferrite core (e) in the opening in the screening plate. Fasten the socket connector with a screwdriver (f). Close the housing top.
e
f
Figure 4-24. Plug in Cables. 4-19
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.16 Installing the Housing Top (Cont.) 5. Center the housing top on the housing base and fasten the 4 screws (b). 6. Insert the sample chamber (a) starting at rear, position at rear, then fasten with screw.
a
7. Place heat shield into position. 8. Insert draft shield, pan , and pan handler. 9. Close cover.
b
Figure 4-25. Housing Top Re-assembly.
4.4 RESETTING THE THERMAL OVERLOAD DEVICE This procedure applies to units containing an access hole that allows the thermal overload protection device to be reset manually. When the dryer has overheated and the thermal overload protection has responded, it may be reset as follows: 1. Disconnect the unit from the power supply. 2. Lift the top cover straight up and remove the access hole cover from the access hole using a flat head screwdriver. 3. Reset the overload device with your finger. See illustrations. 4. Replace the access hole cover and reconnect unit to power supply.
Figure 4-26. Resetting Thermal Overload Device. 4-20
CHAPTER 4 MAINTENANCE PROCEDURES 4.5 FINAL WORK STEPS – Set original customer configuration. – Attach peripheral units. – Perform weight and temperature calibration. – Adjust dryer with Ohaus temperature calibration kit, if not available, drying with a coin as sample; 160 °C for 15 minutes: Display of moisture: 0.000 g ± 0.005g
4-21
CHAPTER 4 MAINTENANCE PROCEDURES
4-22
CHAPTER 5 DRAWINGS AND PARTS LISTS 5.1 DRAWINGS AND PARTS LISTS This section of the manual contains exploded views of the top housing, bottom housing and dryer unit with associated parts lists. NOTE: In all cases where a part is replaced, the Moisture Analyzer must be thoroughly checked after the replacement is made. The Moisture Analyzer MUST meet the parameters of all applicable specifications in this manual.
If further technical information is needed, in the United States call Ohaus Aftermarket toll-free 1-800-526-0659 between 8.00 a.m. and 5:00 p.m. EST. An Ohaus factory service technician will be available to provide assistance. Outside the U.S.A., please : Ohaus Corporation 19A Chapin Road P.O. Box 2033 Pine Brook, NJ 07058-2033, USA Tel: (973) 377-9000 Fax: (973) 944-7177
5-1
CHAPTER 5 DRAWINGS AND PARTS LISTS 5.1.1 Top Housing
1
4
2
3
5
6
9
7
11 8
10
35
Figure 5-1. Top Housing. 5-2
CHAPTER 5 DRAWINGS AND PARTS LISTS TABLE 5-1. SPARE PARTS LIST TOP HOUSING Item
Description
Part Number
1
Sample pan handler (accessory, 3 pieces)
214526
2
Sample pan holder
214642
3
Draft shield, clean out tray
214368
4
Heat shield
11113360
5
Sample chamber
11113359
6
Membrane keypad
11113356
7
Top housing with keypad (without display)
11113862
8
Display
11113772
9
Safety pin
11113367
10
Spring for safety pin
11600360
11
Fan
11113770
5-3
CHAPTER 5 DRAWINGS AND PARTS LISTS 5.1.2 Bottom Housing
12 13 14
24
15
22
19
17
23
18
21
16 20
Figure 5-2. Bottom Housing. 5-4
CHAPTER 5 DRAWINGS AND PARTS LISTS TABLE 5-2. SPARE PARTS LIST BOTTOM HOUSING Item Description 12 Seal for housing top
Part Number 11113362
13
Weighing cell incl. EEPROM (Item 18) and seal
11113850
14
Seal for weighing cell
11600363
15
Power supply board
11113780
16
U board
11113853
17
Battery 3 V, Lithium, CR 2032 or equivalent
18
Cell EEPROM 1)
11103757+SNR
19
Cable U – power supply
11113773
20
Bottom housing
11113350
21
Leveling screw
11101302
22
Level
11101335
23
Microfuse cap (fuse T6,3 A/250 V)
89290
24
Line cable (accessory)
6569-00, 120V US
24
Line cable (accessory)
76212-00, 220V EU
24
Line cable (accessory)
76448-00, 240V UK
24
Line cable (accessory)
76199-01, 240V AUS
See Note
1) The order has to contain the serial number SNR of the balance! NOTE: battery is not available as a replacement part. Must source locally.
5-5
CHAPTER 5 DRAWINGS AND PARTS LISTS 5.1.3 Dryer Unit
25
36 26
27
28 32 29
30
33
35 34
Figure 5-3. Dryer Unit.
5-6
CHAPTER 5 DRAWINGS AND PARTS LISTS TABLE 5-3. SPARE PARTS LIST DRYER UNIT Item
Description
Part Number
25
Reflector
214382
26
Protective glass
214360
27
Halogen radiator110V Halogen radiator 230V
214417 214418
28
Heating module110V Heating module 230V
11113500 11113501
29
Temperature sensor
214349
30
Thermal overload device
214698
32
Dryer unit
11113555
33
Dryer unit hinge left
11600358
34
Dryer unit hinge right
11600357
35
Dryer unit cable
11113771
36
Dryer unit cover
11113503
5-7
CHAPTER 5 DRAWINGS AND PARTS LISTS
5-8
APPENDIX A SOFTWARE SERVICE TOOL INSTRUCTIONS A.
SERVICE NOTES
A.1 Software Service Tool Instructions This software tool is used when a new Main PCB is installed to: 1. Configure the Main PCB. 2. Enter balance serial number 3. Install the application software
SOFTWARE LEGEND MB45 GLOBAL 11670614x.MOT MODEL WHERE USED SOFTWARE FILE REVISION
A.2 Requirements 1. File: MB45 Service Tool Install.zip 2. Application Software File: a. MB45 Global 11670614x.mot b. MB35 Europe 11670806x.mot c. MB35 Latin America 802509712.mot d. MB35 US 11670787x.mot 3. A PC running Windows 95 to XP 4. Interface cable Ohaus part number 80500525 (Serial extension cable)
A.3 Instructions and Notes 1. To open click on the zip file 2. Find the setup file (Setup.exe) and click on it. 3. Follow the instructions. 4. Copy the application software file to the desktop. This is not required but will make the file easier to find later. 5. It is advisable to hook up the balance to HyperTerminal and make sure it is communicating. You will need a standard 9 pin serial extension cable, Ohaus part number 80500525 to connect to your PC. 6. Find “MB45 Service Tool” in the program files and click it to start. 7. The screen below will open.
8. Match the serial port parameters to the balance. Balance defaults are shown above. 9. Click on the tab “Main Board Replacement”
A-1
APPENDIX A SOFTWARE SERVICE TOOL INSTRUCTIONS
10. Click on the button that matches the balance. 11. Enter the serial number of the balance. 12. Enter the TDNR number of the balance. Note: The serial number and TDNR number are printed on a label on the back of the balance. 13. CAUTION – Confirm the information entered above. This programming can only be done once. If you have made and error, click the button “Abort Data Entry” then reenter the data. 14. When the above information has been confirmed click the “Start” button. The following screen will open to indicate the new main board has been configured.
15. Click on the “” Tab. 16. Browse to the required Application Software file (mot file).
A-2
APPENDIX A SOFTWARE SERVICE TOOL INSTRUCTIONS 17. Press the start button.
18. If there is a problem press the red button a. The red button is intended to the data for the very first time or to a blank EEPROM. It is also intended to be used as a last resort if the start button fails. b. Using the start button will save the existing ’s test library, using the red button will not. c. After the red button is clicked you will see a screen that says “Please cycle power to scale…”. At this time unplug the scale from the AC line for about 30 seconds and plug it back in. The will then take about 3 minutes. When it is complete the message “File is SUCCESSFUL”(Checksum=xxxxxxx) will be displayed. If the message “Application code has FAILED” is shown click the OK button and click the red button again. The second time it should work.
A-3
APPENDIX A SOFTWARE SERVICE TOOL INSTRUCTIONS When the software has been ed the following screen will be shown.
A.4 Error Messages
Indicates the computer can not establish a connection to the balance.
Indicates the main board has already been configured. A main board can be configured only once and can not be reconfigured.
Indicates the TDNR number does not match the balance configuration selected. Click “Abort Data Entry” then re-enter the correct data.
A-4
MB45 MOISTURE ANALYZER
SERVICE MANUAL P/N 80250897 A
MB45 MOISTURE ANALYZER SERVICE MANUAL
Ohaus Corporation 19A Chapin Road, P.O. Box 2033, Pine Brook, NJ 07058-2033 (973) 377-9000
SERVICE MANUAL
MB45 MOISTURE ANALYZER
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Ohaus Corporation 19A Chapin Road P.O. Box 2033 Pine Brook, NJ 07932-0900 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 2006 Ohaus Corporation, all rights reserved. ® ed trademark of Ohaus Corporation.
TABLE OF CONTENTS CHAPTER 1 INTRODUCTION Page 1.1 Introduction .......................................................................................... 1-1 1.2 Service Facilities .................................................................................... 1-1 1.3 Tools and Test Equipment Required ...................................................... 1-2 1.3.1 Special Tools .................................................................................. 1-2 1.3.2 Tools and Supplies ........................................................................ 1-2 1.4 Test Mass Required ................................................................................ 1-2 1.5 Specifications ......................................................................................... 1-2 1.5.1 issable Ambient Conditions ..................................................... 1-2 CHAPTER 2.1 2.2 2.3
2 OPERATION Menu Structure .................................................................................. 2-1 Control Switch Functions................................................................... 2-2 Adjusting the Display Contrast and Brightness ................................. 2-3
CHAPTER 3 TROUBLESHOOTING 3.1 Troubleshooting ...................................................................................... 3-1 3.2 Troubleshooting Guide ........................................................................... 3-1 3.2.1 Diagnosis ........................................................................................ 3-1 CHAPTER 4 MAINTENANCE PROCEDURES 4.1 Preventive Maintenance ......................................................................... 4-1 4.1.1 Visual Inspection ............................................................................ 4-1 4.1.2 Preventive Maintenance Checklist.................................................. 4-1 4.2 Testing .......................................................................................... 4-2 4.2.1 Operational Test ............................................................................. 4-2 4.2.1.1 Display Test ...................................................................... 4-2 4.2.2 Weight Calibration .......................................................................... 4-3 4.2.3 Temperature Calibration ................................................................. 4-4 4.2.4 Performance Tests .......................................................................... 4-5 4.2.4.1 Precision Test ................................................................... 4-5 4.2.4.2 Off-Center Load Test ......................................................... 4-6 4.2.4.3 Centered Load Test ........................................................... 4-6 4.2.4.4 Visual Inspection ............................................................... 4-6 4.3 Repairing the Moisture Analyzer ............................................................. 4-6 4.3.1 Repairing the Drying Unit ............................................................... 4-7 4.3.1.1 Dismantling the Heating Module ....................................... 4-7 4.3.2 Replacing the Protective Glass and Reflector................................. 4-8 4.3.2.1 Replacing the Protective Glass and Reflector ................... 4-8 4.3.2.2 Installing Protective Glass and Reflector ........................... 4-8 4.3.3 Replacing the Halogen Lamp ......................................................... 4-8 4.3.3.1 Dismantle Halogen Lamp .................................................. 4-8 4.3.3.2 Installing the Halogen Lamp .............................................. 4-9 4.3.4 Replacing the Temperature Controller ............................................ 4-9 4.3.5 Replacing the Temperature Sensor .............................................. 4-10 i
TABLE OF CONTENTS (Cont.) CHAPTER 4 MAINTENANCE PROCEDURES (Cont.) 4.3.6 Installing the Heating Module ....................................................... 4-10 4.3.7 Removing Housing Top ................................................................ 4-11 4.3.8 Removing the Membrane Keypad ................................................ 4-13 4.3.9 Installing the Membrane Keypad .................................................. 4-13 4.3.10 Replacing the Display ................................................................... 4-14 4.3.11 Replacing the Fan ........................................................................ 4-14 4.3.12 Replacing the U Board ............................................................ 4-15 4.3.13 Replacing the Power Supply Board .............................................. 4-16 4.3.14 Replacing the Weighing Cell ........................................................ 4-17 4.3.15 Replacing the Housing Base ........................................................ 4-18 4.3.16 Installing the Housing Top .............................................................. 4-19 4.4 Resetting the Thermal Overload Device ................................................ 4-20 4.5 Final Work Steps ................................................................................... 4-21 CHAPTER 5 DRAWINGS AND PARTS LISTS 5.1 Drawings and Parts Lists ........................................................................ 5-1 5.1.1 Top Housing ................................................................................... 5-2 5.1.2 Bottom Housing .............................................................................. 5-4 5.1.3 Dryer Unit ........................................................................................ 5-7 APPENDIX A SOFTWARE SERVICE TOOL INSTRUCTIONS A.1 Software Service Tool Instructions ...................................................... A-1 A.2 Requirements ...................................................................................... A-1 A.3 Instructions and Notes ......................................................................... A-1 A.4 Error Messages ................................................................................... A-4
ii
TABLE OF CONTENTS (Cont.) LIST OF TABLES TABLE NO. 1-1 2-1 3-1 4-1 5-1 5-2 5-3
TITLE
PAGE NO.
Specifications ................................................................................. 1-2 Menu structure ................................................................................ 2-1 Diagnostic Guide ............................................................................ 3-2 Types of Performance Tests ........................................................... 4-5 Spare Parts List Top Housing ......................................................... 5-3 Spare Parts List Bottom Housing .................................................... 5-5 Spare Parts List Dryer Unit ............................................................. 5-7 LIST OF ILLUSTRATIONS
FIGURE NO.
TITLE
PAGE NO.
4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22 4-23 4-24 4-25 4-26
Access for Cleaning MB45 Moisture Analyzer ................................ 4-1 Display Test .................................................................................... 4-2 Dismantling the Heating Module ..................................................... 4-7 Removing the Heating Module ....................................................... 4-7 Replacing Protective Glass ............................................................ 4-8 Replacing Halogen Lamp ............................................................... 4-8 Installing the Halogen lamp ............................................................ 4-9 Replacing Temperature Controller.................................................. 4-9 Replacing Temperature Sensor .................................................... 4-10 Installing Heat module .................................................................. 4-10 Replacing Cover ........................................................................... 4-11 Remove Housing .......................................................................... 4-11 Remove Cable from Display ......................................................... 4-12 Remove Connectors ..................................................................... 4-12 Remove Membrane Keypad ......................................................... 4-13 Install Membrane Keypad ............................................................. 4-13 Replacing Display ........................................................................ 4-14 Replacing Fan .............................................................................. 4-14 Replacing U Board .................................................................. 4-15 Replacing Power Supply Board.................................................... 4-16 Replacing Weighing Cell .............................................................. 4-17 Replace Housing Base ................................................................. 4-18 Install Housing Top ....................................................................... 4-19 Plug in Cables .............................................................................. 4-19 Housing Top Reassembly .............................................................. 4-20 Resetting the Thermal Overload Device ........................................ 4-20
5-1 5-2 5-3
Top housing .................................................................................... 5-2 Bottom Housing .............................................................................. 5-4 Dryer Unit ........................................................................................ 5-6 iii
iv
CHAPTER 1 INTRODUCTION 1.1 INTRODUCTION This service manual contains the information needed to perform routine maintenance and service on the Ohaus MB45 Moisture Analyzer. The contents of this manual is contained in five chapters.
Chapter 1 Introduction - Contains information regarding service facilities, tools and test equipment, measuring masses, and specifications.
Chapter 2 Operation - Contains information on the control functions of the Moisture Analyzer. Chapter 3 Troubleshooting - Contains a diagnosis/diagnostics chart and error code table. Chapter 4 Maintenance Procedures - Contains preventive maintenance procedures, performance tests and adjustments, disassembly/replacement procedures, and calibration procedures. Chapter 5 Drawings and Parts Lists - Contains exploded views of all assemblies identifying serviceable components with parts lists. Before servicing the Moisture Analyzer, you should be familiar with the Instruction Manual which is packed with every unit.
1.2 SERVICE FACILITIES To service the Ohaus MB45 Moisture Analyzer, the service area should meet the following requirements: DO NOT SERVICE the Moisture Analyzer: • Next to open windows or doors causing drafts or rapid temperature changes. • Near air conditioning or heat vents. • Near vibrating, rotating or reciprocating equipment. • Near magnetic fields or equipment that generates magnetic fields. • On an unlevel work surface. • Allow sufficient space around the instrument for ease of operation and keep away from radiating heat sources.
On/O Test Displa y Setup
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STAR T/STO
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STAR T/STO P
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1-1
CHAPTER 1 INTRODUCTION 1.3 TOOLS AND TEST EQUIPMENT REQUIRED This section contains information on tools and supplies required to properly service the MB45 Moisture Analyzer. These items are listed as follows:
1.3.1 Special Tools None required.
1.3.2 Tools and Supplies 1.Digital Voltmeter (DVM) - Input impedance of at least 10 megohms in the 1 Volt dc position. 2.Standard electronics tool kit 3.Soldering iron (50 watt) and solder (rosin core solder, not acid core). 4.Solder remover. 5.Ohaus Temperture Calibration Kit P/N 11113857 6.Soft, lint-free cleaning cloth 7.Anti-static bags for PCBs 8.Anti-static wrist strap and mat
1.4 TEST MASS REQUIRED It is recommended that a ASTM Class 1 Tolerance mass be used. The mass required is 20 grams.
1.5 SPECIFICATIONS Complete specificatons for the MB45 Moisture Analyzer are listed in Table 1-1. When an MB45 has been serviced, it must meet the specifications listed in Table 1-1. Before servicing the Moisture Analyzer, determine what specifications are not met.
TABLE 1-1. SPECIFICATIONS Capacity Readability Heat Source Calibration Dimensions (DxWxH) (in/cm) Operating Temperature Range Power Requirements Weight (lb/kg) Shipping Weight (lb/kg)
45g 0.001g, .01% Halogen bulb - 120 V or 240 V External calibration mass-20g 14 x 7.5 x 7/ 35.5 x 19 x 17.8 10°C to 40°C 100V ac -127V ac or 230V ac - 240V ac, 50/60Hz 9.8 / 4.5 14.1 / 6.4
1.5.1 issible Ambient Conditions Temperature range: Atmospheric humidity: Voltage fluctuations: Installation category: Pollution degree: Power load: Current consumption: Power supply voltage: Power line fuse:
Use only in closed rooms 5 ºC to 40 ºC 80% rh @ to 30 ºC –15% +10% II 2 Max. 450 W during drying process 4 A or 2 A, according to the heating element 100 V – 120 V or 200 V – 240 V, 50/60 Hz (the voltage is given by the heating element) 1 piece, 5 x 20 mm, T6,3 H 250 V
1-2
CHAPTER 2 OPERATION 2.1 MENU STRUCTURE This chapter contains menu structure, control swich operation and display adjustments. For complete operation, refer to the Instruction manual supplied with the unit. The menu structure is illustrated in the table below.
TABLE 2-1. MENU STRUCTURE
TEST MENU
SETUP
Test Library
Setup
Edit Test Test Parameters 01 Test ID: Load Test Profile: Edit Test Standard Delete Test Fast 02 Ramp Load Test Step Edit Test Dry Temp: Delete Test Switch Off: • Timed- Switch Off • Manual-Use Start/Stop • AFREE - Wt loss/time • A90 - <1MG in 90 seconds 50 A60 - <1MG in 60 seconds Load Test A30 - <1MG in 30 seconds Edit Test Result: Delete Test % Moisture Custom Units Grams % Regain % Solids Custom Factor, Exponent, LSD Target Wt: Print Int: Off, 1, 3, 5, 10, 30 Sec 1, 2, 5 Min. Save Test:
Lockout Weight Calibration Temperature Calibration Language English, Deutsch, Espaniol, Francais, Italiano Beeper Low, High, Off Time-Date Format MM/DD/YR, DD/MM/YR Set Date Time format 12HR, 24HR Set Time AM, PM RS232 Baud Rate 1200, 2400, 4800, 9600, 19,200 Parity Odd, Even, None Data Bits 7, 8 Stop Bits 1, 2 Handshake None, XON-XOFF, RTS-CTS Print Print On/Off GLP On/Off Display Contrast Brightness Factory Reset
2-1
CHAPTER 2 OPERATION 2.2 CONTROL SWITCH FUNCTIONS
6
1 2
On/Off
7
0%
8
Test Menu Display
3
On/
Setup
Enter
Test
9
Dis Setu
p
play
Men
Off
u
MB
45
STA
RT/ S
TO
4
START/STOP
TARE
P
10 Ente
11
5
No.
Designation
1
r Prin
TAR
t
E
12 11
Function Turns ON/OFF display and fan. ON returns with last screen. (All modes)
2
Test Menu button
When pressed, selects Test Library screen.
3
Display button
When pressed, will return to the current test or cycles through several display screens (run mode).
4 5 5
Setup button
When pressed, brings up analyzer setup menu.
Start/Stop button
When pressed, either starts or stops drying process.
6
button
When pressed, travels up through menu options and selects alphanumeric characters.
7
button
When pressed, travels to the left through displays.
8
button
When pressed, travels to the right through displays.
9
button
When pressed, travels down through menu options and selects alphanumeric characters.
110
Enter/Print button
When pressed, accepts selection/input (select mode) or sends print command during a test (run mode).
11
Tare button
When pressed, performs a tare function. Pressing during a test has no effect.
12
Leveling feet
Used to level the Moisture Analyzer.
2-2
CHAPTER 2 OPERATION 2.3 ADJUSTING THE DISPLAY CONTRAST AND BRIGHTNESS Enter the ANALYZER SETUP menu, this menu permits adjusting the contrast and brightness levels on the display screen. To change the levels, proceed as follows:
ANALYZER SETUP LANGUAGE BEEPER TIME-DATE RS-232 PRINT DISPLAY
DISPLAY ADJUST CONTRAST:
60
BRIGHT:
10
Press the Setup button. Using the down arrow button, scroll to DISPLAY. Press the Enter button.
Adjusting contrast Using the up/down arrow buttons, adjust the screen contrast to the desired level. The numeric value (0 to 100) is for reference only. Press the right arrow button to advance to BRIGHT. Default = 40.
EXIT WITHOUT SAVING
DISPLAY ADJUST CONTRAST:
60
BRIGHT:
10
Adjusting brightness Using the up/down arrow buttons, adjust the screen brightness to the desired level. The numeric value (0 to 10) is for reference only. Press the Enter button. Default = 10.
EXIT WITHOUT SAVING
DISPLAY ADJUST CONTRAST:
60
BRIGHT:
10
Exit without saving If you do not wish to save settings, Use the right arrow button and scroll to EXIT WITHOUT SAVING and press the Enter button. The display returns to ANALYZER SETUP.
EXIT WITHOUT SAVING
2-3
CHAPTER 2 OPERATION
2-4
CHAPTER 3 TROUBLESHOOTING 3.1 TROUBLESHOOTING This section of the manual specifies problem areas of the MB45 Moisture Analyzer which can occur. Information is contained to isolate specific problems using the Troubleshooting Guide. Make certain that the work area is clean and use care when handling components of the Analyzer.
3.2 TROUBLESHOOTING GUIDE A Troubleshooting Guide is designed to help you locate the problem area quickly and easily. First locate the problem that you are observing. The probable causes are listed with the most common cause first. Before attempting to repair the Analyzer, read all chapters of this manual to familiarize yourself with the components and operation. Do not attempt repairs unless you fully understand the operation of the Analyzer.
3.2.1 Diagnosis 1.Isolate and identify the symptom. 2.Review the probable causes in the order that they appear. 3.See the appropriate section of the manual to correct the malfunction. 4.Repair or replace the defective section of the Moisture Analyzer. NOTE: If more than one symptom is observed, it is necessary to approach one area at a time, and also , that the symptoms may be interrelated. In the event that erratic or fluctuating weight readings are observed, it is necessary to isolate the problem to either the mechanical area or the electronic area of the Moisture Analyzer. If a problem arises that is not covered in this manual, :
Ohaus Corporation 19A Chapin Road P.O. Box 2033 Pine Brook, NJ 07058-2033 USA Tel: 973-377-9000 Fax: 973-944-7177
In the United States call toll free, 800-526-0659 between 8:00 a.m. and 6:00 p.m. EST.
3-1
CHAPTER 3 TROUBLESHOOTING 3.2 TROUBLESHOOTING GUIDE (Cont.)
TABLE 3-1. DIAGNOSTIC GUIDE SYMPTOM Moisture analyzer cannot be switched on. Moisture analyzer cannot be switched on green LED on power supply board does not light up.
Moisture analyzer cannot be switched on. Green LED on power supply board lights up.
PROBABLE CAUSE(S)
REMEDY
Power cord not plugged in or no power Check supply voltage. The power supply is designed for 100...240 VAC, but the drying unit only Defective main fuse. for 110 or 230VAC. Check whether the correct drying unit is installed. Check Defective power supply fuse. the fuses on the back of the instrument and the power supply board. Cable connections inside instrument not Plug in or replace cable. plugged in or defective. Defective U board.
Replace U board.
Moisture analyzer cannot be switched on green LED on power supply board does not light up.
Defective power supply fuse. Defective power supply board.
Replace power supply fuse on power supply board. Replace power supply board.
Some buttons do not respond.
Defective keypad wiring.
Replace membrane keypad.
Keypad does not function.
Keypad not plugged in
Check keypad.
Defective keypad wiring
Replace membrane keypad.
Portions of the display do not light up.
Defective display.
Replace display.
Halogen lamp does not switch on after "Start".
Thermal overload device has tripped.
Reset thermal overload device, see paragraph 4.4.
Defective temperature controller.
Replace if resistance after resetting is > 1 Ohm. Replace if resistance > 20 Ohms (check whether 100 or 230 VAC).
Defective halogen lamp.
Temperature sensor not plugged in or Plug in or replace sensor. defective. Defective power supply board.
Replace power supply board.
Defective U board.
Replace U board.
Halogen lamp switches off before end of test.
Incorrect Halogen bulb
Check voltage rating on bulb.
Temperature rises above 205 degrees C.
Defective temperature sensor. Defective power supply board. Defective U board.
Replace temperature sensor. Replace power supply board. Replace U board.
Unstable weight indication.
The air current which cools the weighing Clean the ventilation grill. cell is blocked.
3-2
CHAPTER 4 MAINTENANCE PROCEDURES 4.1 PREVENTIVE MAINTENANCE Ohaus MB45 Moisture Analyzers are precision instruments and should be carefully handled, stored in a clean dry area which is dust free, and cleaned periodically. It is recommended that when a Analyzer has had chemicals or liquids spilled on it, the Analyzer should be cleaned as soon as possible. Use warm water on a damp cloth to clean all exterior surfaces. Do not leave a mass on the sample pan when the Analyzer is not in use. When moving the unit from a storage area which is at a different temperature than the area where it is to be operated, allow sufficient time for the mechanism to temperature stabilize. This time can vary quite a bit depending upon the temperature differences. Allow one (1) hour for each 5 degrees Fahrenheit temperature change before using the Moisture Analyzer. Also, after turning the Analyzer ON, allow five minutes after temperature stabilization for the internal electronics to stabilize.
4.1.1 Visual Inspection When a Moisture Analyzer is first received for repairs, the unit should be checked visually for completeness. — Check on completeness in accordance with standard equipment. — Check on the condition of the following parts: • Housing • Keypad and display • Draft shield with heat shield, pan handler and pan • Dryer unit with protective glass, Halogen radiator, reflector • Fan grill (rear) • Leveling feet and level • Rating plate
4.1.2 Preventive Maintenance Checklist On a regular basis, the MB45 Moisture Analyzer should be inspected and checked as follows: 1.Remove power from the MB45.
2.Remove the Pan , Draftshield and Heatshield and inspect the interior and exterior of the Moisture Analyzer. 3.Clean the outside of the Moisture Analyzer using a damp cloth with water or a mild household detergent. 4. Remove any debris which may have accumulated under the pan or shields.
Glass Shield Pan Draft Shield Heat Shield
5.Inspect the protective glass shield and clean any spattered material which may have accumulated on the glass. 6.Inspect fan opening for excessive dust.
Figure 4-1. Access for Cleaning MB45 Moisture Analyzer. 4-1
CHAPTER 4 MAINTENANCE PROCEDURES 4.1.2 Preventive Maintenance Checklist (Cont.) CAUTION DO NOT USE CHEMICAL CLEANERS OR SOLVENTS OF ANY TYPE. SOME CLEANERS ARE ABRASIVE AND MAY AFFECT THE FINISH OF THE ANALYZER. 7.Check the Power Cord for broken or damaged insulation. 8.Make a visual inspection for faulty connectors, wiring, and loose hardware.
4.2 TESTING Before servicing the MB45 Moisture Analyzer, an operational test and various performance tests should be made to ascertain whether or not the unit meets specifications. Turn the Moisture Analyzer on and allow it warm up for at least one hour before performing these tests. Make sure the test area is free from drafts and the surface that the Moisture Analyzer rests on is level and vibration free. It is recommended that a ASTM Class 1 Tolerance mass be used for the performance tests and adjustments.
4.2.1 Operational Test 1.Locate a suitable power source for the Moisture Analyzer. Check the voltage rating of the Moisture Analyzer. 2.Plug the Power Cord into a suitable power source. NOTE: If possible, record original customer settings so that after repairs, the Moisture Analyzer can be returned in a satisfactory operational mode.
4.2.1.1 Display Test 1.Turn the Moisture Analyzer on, a MB45 Moisture Analyzer display with the Ohaus logo should appear followed by the software revision currently installed in the Moisture analyzer. After this display, a standard display appears. This is a display test. Figure 4-2 is a full display test. The software revision will only appear after plugging in the analyzer for the first time. Subsequent power on using the On/Off button will not display the software revision. 2.Press the TARE button. The display should indicate a zero weight.
®
Sr 1.06b TEST ID: TEMP/TIME: TARG. WGT:
-DEFAULT100C / 10:00 1 GRAMS
CLEAR PAN PRESS TARE
0.000 * GRAMS
Figure 4-2. Display Test. 4-2
CHAPTER 4 MAINTENANCE PROCEDURES 4.2.2 Weight Calibration The Moisture Analyzer can be span calibrated with an external mass of 20 grams. Calibration of the Moisture Analyzer balance is not absolutely necessary for a correct moisture determination as the measurement is relative. The balance determines the weight of the sample before and after drying and the moisture is calculated on the basis of the ratio between wet and dry weights. Nevertheless, you should calibrate the built-in balance under the following conditions: — If this is stipulated by your quality assurance system (GLP, GMP, ISO 9001). — If you suspect the analyzer has been abused. — Before and after all repairs. To calibrate the Analyzer, proceed as follows:
ANALYZER SETUP LOCK OUT WEIGHT CAL TEMP CAL LANGUAGE BEEPER TIME-DATE
Clear the pan handler, a sample pan should be in place, close the cover on the Moisture Analyzer. Press the Setup button. Using the arrow buttons, scroll to WEIGHT CAL. Press the Enter button. The display screen highlights the action you should take.
WEIGHT CAL PLACE 20G MASS
Place the required weight on the sample pan, close the cover. Follow the instructions on the display. The display indicates if the calibration was successful.
TO ABORT PRESS STRT/STP KEY
Press the Display button to return to display. To abort, press START/STOP button.
4-3
CHAPTER 4 MAINTENANCE PROCEDURES 4.2.3 Temperature Calibration You must have an Ohaus Temperature Calibration Kit, (Part Number 11113857) to perform this procedure. If the Moisture Analyzer has been recently used, allow at least 30 minutes before performing calibration.
ANALYZER SETUP LOCK OUT WEIGHT CAL TEMP CAL LANGUAGE BEEPER TIME-DATE
NOTE: The Temperature Calibration Kit is available as optional equipment. Press the Setup button. Using the arrow buttons, scroll to TEMP CAL. Press the Enter button. You are now prompted to remove the pan handler and pan . Replace the pan handler and place a temperature calibration unit on the pan handler.
TEMP CAL
NOTE: The unit will not calibrate with the pan in place.
REMOVE PAN HANDLER AND PAN ABORT CALIBRATION
Press the Enter button to initiate the temperature calibration process. Follow the screen prompts throughout the process.
TEMP CAL 100C CURRENT TEMP: TM TO CAL POINT:
--- C 15:00 MIN
The dryer unit is heated to a temperature of 100°C. You can observe the progress on the display as the dryer temperature and count down period are displayed. After 15 minutes, read the thermometer through the inspection window on the cover and enter this temperature. Using the up/down arrow buttons, adjust the display reading to agree with the thermometer. Use the left/right arrow buttons to highlight ACCEPT NEW CAL, then press the Enter button. You have 10 minutes to make this adjustment, otherwise the calibration is terminated.
ADJ CAL READING: 100 C ACCEPTS NEW CAL ABORT CALIBRATION
TEMP CAL 160C CURRENT TEMP: TM TO CAL POINT:
100 C 15:00 MIN
ADJ TO CAL READING: 160 C ACCEPTS NEW CAL ABORT CALIBRATION
This is a two point adjustment (100°C and 160°C). The dryer unit now heats to the second temperature (160°C). Adjustment of the temperature is defined by two points. Proceed exactly as you did for the first temperature. After you have set the display to agree with the thermometer, highlight ACCEPT NEW CAL, then press the Enter button. The display returns to ANALYZER SETUP.
WARNING: Be careful when removing the temperature calibration unit from the dryer unit as it can be very hot. Allow it to cool down by opening the cover before removing. Remove the calibration unit. Replace the pan and the pan handler in their proper positions.
4-4
CHAPTER 4 MAINTENANCE PROCEDURES 4.2.4 Performance Tests Accurate performance of the MB45 Moisture Analyzer is determined by a series of three performance tests. Precision, Off Center Load and Centered Load. The displayed readings are compared with the tolerances listed in Table 4-1. Tolerance values are expressed in grams. Before starting the performance tests, level the Moisture Analyzer.
TABLE 4-1. TYPES OF PERFORMANCE TESTS PERFORMANCE TEST
TOLERANCE
Precision (Standard Deviation)
0.0015g
Off Center Load
+0.004g
Centered Load
+0.004g
The following performance tests are used to evaluate the Moisture Analyzer operation before and after repairs. Each Moisture Analyzer tested must meet the requirements specified in each test as well as the specifications listed in Table 1-1. Before proceeding with the following tests, all the procedures starting with paragraph 4.2 must have been accomplished on the Moisture Analyzer first. Tolerance values are expressed in counts. A Moisture Analyzer which es each of these three tests meets the manufacturing specifications.
4.2.4.1 Precision Test Precision is a word used in balance specifications meaning the Standard Deviation of a set of similar weight readings. To determine whether an Analyzer meets the calculated Standard Deviation value in the Specification Table 1-1, perform the following test:
Test 1.Tare the Analyzer. The reading on the display should be 0.000g. 2.Place a 20g mass on the center of the sample pan. Observe and record the reading when the stable indicator come on. 3.Remove the mass. Reading should return to 0g +0.002g when the stable indicator is on. 4.Repeat this test for ten readings. If the standard deviation of the readings is less than 0.0015g, the Moisture Analyzer es the Precision Test. CAUTION: Remove the mass from the pan after testing.
Adjustment If the deviation for any set of readings (using the same mass placed on the center of the pan) is greater than 0.0015g, the Moisture Analyzer does not meet the Precision Test specification. Inspect and correct the following areas: 1.Check for mechanical obstructions. Any foreign object touching any part of the moving pan linkage assembly will cause a Moisture Analyzer to fail the Precision Test. Inspect and correct as necessary. 2.An error in the Off-Center Load Test can affect the results of the Precision Test. Inspect and correct if necessary. See Off-Center Load Test. 3.Foreign material or debris located in the balance between the pan and the base will cause the Moisture Analyzer to fail the test. 4.Environmental influences such as vibrations, drafts or a non-level surface can cause failures.
4-5
CHAPTER 4 MAINTENANCE PROCEDURES 4.2.4.2
Off-Center Load Test
The Off-Center Load Test is used to determine whether displayed weight values will be affected by moving the sample to different areas of the sample pan. (NOTE: Due to the use of relative weighing in moisture analysis, off center load performance is not critical.)
Test 1.Place a sample pan on the pan handler. 2.Place 1/2 of the Moisture Analyzer capacity (20 gramms) in the center of the sample pan. 3.Press the TARE button to return the reading to zero. 4.Move the mass halfway (between the center and the edge) to the front of the sample pan. Note any differences in the displayed weight reading. 5.Repeat this test for the back, left, and right positions. 6.Maximum allowable change in displayed weight readings is +0.004g for each of the four positions. If this reading is exceeded, it usually indicates a defective Weighing Cell.
4.2.4.3 Centered Load Test This test is used to determine the linearity of the unit throughout its operating range. NOTES: 1. Due to the use of relative weighing and limited use of the weighing range in moisture analysis, linearity performance is not critical. 2. The Moisture Analyzer must the Off-Center Load Test and Precision Test before the Centered Load Test may be performed.
Test 1.Place a 20g mass on the center of the sample pan and note the reading. 2.If the displayed weight is greater than 0.002g higher or lower than the value of the applied mass, and recalibrate the Moisture Analyzer. The Moisture Analyzer should now be calibrated in grams. 3.After completing the above adjustments, check the linearity at 10g and 20g. The displayed weight readings should be equal to the applied mass. Tolerance is +0.004g for each of the respective weight readings. If the displayed weight values are in excess of tolerance count, the Weighing Cell must be replaced.
4.3 REPAIRING THE MOISTURE ANALYZER Disconnect from power supply and allow heating module to cool ! Important: Electrostatic protection when servicing !
Electrostatic damage is difficult to detect, because the faults it causes are not clear cut. MOS switching transistors with electrostatic damage have substantially higher, thermically unstable leakage currents. As a result, the Moisture Analyzer balance drifts more and the display can fluctuate similar to when there is a draft. To avoid electrostatic damage during production, conducting floors, controlled air humidity, and EMC mats are used. When servicing is carried out it is therefore also advisable – as soon as the instrument is opened – to neutralize electrostatic charges. 4-6
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.1 Repairing the Drying Unit 4.3.1.1 Dismantling the Heating Module 1. Swivel drying unit upward. 2. Unscrew 4 screws (a). 3. Pull cover off toward back.
a
Figure 4-3. Dismantling the Heating Module.
4. Unscrew 2 screws (b).
b
5. Lift heating module out. 6. Disconnect heater cable at 2 connectors (c).
c
Figure 4-4. Removing the Heating Module. 4-7
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.2 Replacing the Protective Glass and Reflector
e
Swivel drying unit up and unscrew cover (d).
4.3.2.1 Removing Protective Glass and Reflector
f
1. Pull reflector (e) up and out. 2. Pull protective glass (f) up and out.
4.3.2.2 Installing Protective Glass and Reflector 1. Insert protective glass with opening pointing down. 2. Insert reflector. 3. Screw cover on (d).
d
Figure 4-5. Replacing Protective Glass. 4.3.3 Replacing the Halogen Lamp 4.3.3.1 Dismantle Halogen Lamp 1. Dismantle the heating module. 2. Dismantle protective glass and reflector. 3. Use both forefingers to spread the clamping springs to the left and right and at the same time use both thumbs to lift the Halogen lamp carefully upward out of the clamping springs (the two ends ot the Halogen lamp must not be bent toward or away from each other, otherwise, the glass tube will break).
Figure 4-6. Replacing Halogen Lamp. 4-8
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.3.2 Installing the Halogen Lamp a CAUTION: Finger oils can cause premature lamp failure. Only touch the black part of the Halogen lamp! If necessary, clean the lamp with a weak organic solvent.
b c
1. Hold the new Halogen lamp by the black ends and insert it into the two metal s (a) at the back. If the metal s have fallen out, replace them so that the wider part of the fork (b) is on top; the metal s must press the Halogen lamp gently against the protective glass (c). 2. Lay the flat,connector side of the Halogen lamp on the clamping springs at the front,use both thumbs to push it about 2 mm toward the back against the metal s and then down to engage in the clamping springs.
Figure 4-7. Installing the Halogen Lamp.
3. Reconnect the 2 connectors of the Halogen lamp. 4. Install the protective glass and reflector. 5. Install the heating module.
4.3.4 Replacing the Thermal Overload Device (Thermal cut-out switch) NOTE: Before replacing the the thermal overload device, it may have tripped and has to be reset. Refer to paragraph 4.4 to reset the thermal overload device.
d e
1. Dismantle the heating module. 2. Use flat-nosed pliers to pull off the two cable connectors. 3. Replace temperature controller (e). Do not forget the spacing washer on the heat-conducting plate (d)! Do not tighten the washer too tight (1.2 Nm). 4. Tighten nut with 1.2 Nm. If the temperature controller has responded,reset with finger (do not push spring under edge of base!).
4-9
Figure 4-8. Replacing Thermal Overload Device.
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.5 Replacing the Temperature Sensor 1. Dismantle heating module. 2. Pull off the connector (a). 3. Remove screw (b) and (c),lift temperature sensor out of its holder and replace minding to
c d
pull the sensor cable through the clamp (d) also see Figure 4-10.
b
a
4. Screw temperature sensor firmly back into place and push connector (a) on again. 5. Install heating module.
Figure 4-9. Replacing Temperature Sensor. 4.3.6 Installing the Heating Module 1. Reconnect the 2 connecting cables (f) and (g) of the heater. e
2. Insert the heating module into the frame and fasten with 2 screws (e). The bare connector (f) carries the 220 V power supply voltage and must therefore always be installed as shown. It must not lie outside the heating module like connector (g).
f
g
Figure 4-10. Installing Heat Module. 4-10
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.6 Installing the Heating Module (Cont.) 3. Replace cover and fasten with 4 screws (a). 4. Swivel drying unit closed.
a
Figure 4-11. Replacing Cover.
4.3.7 Removing Housing Top 1. Remove pan handler, pan , and draft shield. 2. Lift heat shield off. 3. Remove screw (a) and then lift the sample chamber, first at the front and then completely.
a
4. Remove the 4 screws (b) from the housing top.
b
Figure 4-12. Remove Housing. 4-11
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.7 Removing Housing Top (Cont.) 5. Lift the front of the housing top then,using a screwdriver, carefully unfasten the connector socket of the keyboard cable (b)and pull off the cable. Pull off the cable of the display (a).
a
b
Figure 4-13. Remove Cable from Display. 6. Lift the housing top until the level indicator (d)is free, then swivel it into the vertical position toward the back to rest against the open cover of the drying unit. 7. Pull off the connectors for the fan (a), temperature sensor (b), and Halogen lamp (c). 8. Put the housing top aside out of the way.
d
a b
c
Figure 4-14. Remove Connectors. 4-12
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.8 Removing the Membrane Keypad 1. Remove the housing top. 2. Release the faulty membrane keypad from the cable side (h). 3. Remove any traces of adhesive (if necessary,use pure benzene). WARNING Benzene is highly flammable, use only in small quantities.
h
Figure 4-15. Remove Membrane Keypad.
4.3.9 Installing the Membrane Keypad Avoid making finger marks and getting dust on the display and window of the membrane keypad! 1. Insert the cable of the new membrane keypad. 2. Pull the covering foil off the adhesive surface. 3. Insert the membrane keypad into the depression in the housing top, starting only with the front, right-hand corner and then with the right-hand edge. Then, roll it toward the left into the depression and press it down. 4. Install the housing top. (See 4.3.16)
Figure 4-16. Install Membrane Keypad.
4-13
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.10 Replacing the display 1. Remove housing top. 2. Unscrew display and remove. 3. Insert new display and fasten with screws. 4. Install housing top. (See 4.3.16)
Figure 4-17. Replacing Display. 4.3.11 Replacing the fan 1. Remove housing top. 2. Unscrew screening plate from housing top.
k
3. Slide cable (i) out through grommet (k), remove grommet (k) from screening plate together with fan connector. 4. Replace fan,taking care to install it in the direction indicated by the arrow printed on it (m).
m
p
5. Assemble the housing top: do not forget the spring (p)! (The pin triggers the safety switchoff if the housing top is opened during operation.)
i
6. Install housing top. (See 4.3.16) 7. Test safety switchoff for correct functioning: • Start drying so the the lamp is lit. • Open the cover of the MB45: the lamp should switch off immediately. If it does not, check whether the spring (p) is pressing the safety pin upward (q): q
Figure 4-18. Replacing Fan. 4-14
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.12 Replacing the U board 1. Remove housing top. 2. Remove screening plate (a). 3. Pull off the connector to the power supply (b), carefully unfasten the socket connector of the weighing cell cable (c), and pull the cable out. a 4. Unscrew the U board and remove. 5. Transfer the cell EEPROM (d) from the old U board, replacing the battery (e) with a new one if necessary (3 V, Lithium,e.g. CR 2032). 6. Install new U board.
b
d
e c
7. Install screening plate (a). 8. Re-insert cables (b)and (c) and fasten. 9. Install housing top. (See 4.3.16) 10. Perform weighing and temperature calibration. 11. After replacing the PC Board, refer to Appendix A and follow the instructions to configure the new PC Board.
Figure 4-19. Replacing U Board.
4-15
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.13 Replacing the power supply board 1. Remove housing top.
f
2. Remove the screw (f) at the back of the screening plate. 3. Pull off the 4 connectors for the U board (g), fan (i), temperature sensor (k) and lamp (m). 4. Remove screw to release ground protection cable (h). 5. Remove the 4 screws from the power supply board and the 2 screws (o) from the RS232 interface socket. Lift the power supply board at the front and remove it.
k i
g m
p
6. Install new power supply board: • First tighten the 2 screws (o) of the RS232 interface socket then the 4 screws with toothed washers of the power supply board. • Screw the eye of the ground protection cable and the toothed washer firmly under the head of screw (h).
h o
r
7. Screw in the back screw (f) of the screening plate. 8. Plug in the 4 connectors. 9. If necessary, replace the main fuse (r)T6.3 A/ 250 V or power supply (p) 500 mA/250 V. 10. Install the housing top. (See 4.3.16)
Figure 4-20. Replacing Power Supply Board.
4-16
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.14 Replacing the Weighing Cell 1. Remove housing top. 2. Remove screening plate (a)and seal (b). 3. Unfasten the socket connector (e) of the cell on the U board and pull out the cable. 4. Unscrew weighing cell (c) and remove. 5. Install new weighing cell in reverse order.
a b
6. Replace cell EEPROM (d). 7. Install screening plate. 8. Install housing top. (See 4.3.16) 9. Perform weight calibration.
d
c
e
Figure 4-21. Replacing Weighing Cell.
4-17
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.15 Replacing the Housing Base 1. Remove housing top. 2. Remove the following parts from the old housing base and install them on the new one:
h
• Leveling screws • U board (c). • Power supply board (d).
g e
• Weighing cell (e). • Level indicator (f) • Seals (g) • Screening plate (h) 3. Install housing top. (See 4.3.16)
d
f
c
Figure 4-22. Replace Housing Base.
4-18
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.16 Installing the Housing Top 1. Lay the housing top toward the back on the opened cover of the drying unit. 2. Insert connectors for fan (a), temperature sensor (b), and Halogen lamp (c). 3. LIft the housing top until it is above the level indicator (d), tilt it into the horizontal position, then over the level indicator and seal and lower it onto the housing base. CAUTION: that cables for fan (a), temperature sensor (b) and Halogen lamp (c) are clear from housing top when installing. Wires can be damaged if not positioned properly and can possibly cause damage to the Moisture Analyzer.
d
a
c
b
Figure 4-23. Install Housing Top.
4. Plug in the cables of the display and keyboard. Position the ferrite core (e) in the opening in the screening plate. Fasten the socket connector with a screwdriver (f). Close the housing top.
e
f
Figure 4-24. Plug in Cables. 4-19
CHAPTER 4 MAINTENANCE PROCEDURES 4.3.16 Installing the Housing Top (Cont.) 5. Center the housing top on the housing base and fasten the 4 screws (b). 6. Insert the sample chamber (a) starting at rear, position at rear, then fasten with screw.
a
7. Place heat shield into position. 8. Insert draft shield, pan , and pan handler. 9. Close cover.
b
Figure 4-25. Housing Top Re-assembly.
4.4 RESETTING THE THERMAL OVERLOAD DEVICE This procedure applies to units containing an access hole that allows the thermal overload protection device to be reset manually. When the dryer has overheated and the thermal overload protection has responded, it may be reset as follows: 1. Disconnect the unit from the power supply. 2. Lift the top cover straight up and remove the access hole cover from the access hole using a flat head screwdriver. 3. Reset the overload device with your finger. See illustrations. 4. Replace the access hole cover and reconnect unit to power supply.
Figure 4-26. Resetting Thermal Overload Device. 4-20
CHAPTER 4 MAINTENANCE PROCEDURES 4.5 FINAL WORK STEPS – Set original customer configuration. – Attach peripheral units. – Perform weight and temperature calibration. – Adjust dryer with Ohaus temperature calibration kit, if not available, drying with a coin as sample; 160 °C for 15 minutes: Display of moisture: 0.000 g ± 0.005g
4-21
CHAPTER 4 MAINTENANCE PROCEDURES
4-22
CHAPTER 5 DRAWINGS AND PARTS LISTS 5.1 DRAWINGS AND PARTS LISTS This section of the manual contains exploded views of the top housing, bottom housing and dryer unit with associated parts lists. NOTE: In all cases where a part is replaced, the Moisture Analyzer must be thoroughly checked after the replacement is made. The Moisture Analyzer MUST meet the parameters of all applicable specifications in this manual.
If further technical information is needed, in the United States call Ohaus Aftermarket toll-free 1-800-526-0659 between 8.00 a.m. and 5:00 p.m. EST. An Ohaus factory service technician will be available to provide assistance. Outside the U.S.A., please : Ohaus Corporation 19A Chapin Road P.O. Box 2033 Pine Brook, NJ 07058-2033, USA Tel: (973) 377-9000 Fax: (973) 944-7177
5-1
CHAPTER 5 DRAWINGS AND PARTS LISTS 5.1.1 Top Housing
1
4
2
3
5
6
9
7
11 8
10
35
Figure 5-1. Top Housing. 5-2
CHAPTER 5 DRAWINGS AND PARTS LISTS TABLE 5-1. SPARE PARTS LIST TOP HOUSING Item
Description
Part Number
1
Sample pan handler (accessory, 3 pieces)
214526
2
Sample pan holder
214642
3
Draft shield, clean out tray
214368
4
Heat shield
11113360
5
Sample chamber
11113359
6
Membrane keypad
11113356
7
Top housing with keypad (without display)
11113862
8
Display
11113772
9
Safety pin
11113367
10
Spring for safety pin
11600360
11
Fan
11113770
5-3
CHAPTER 5 DRAWINGS AND PARTS LISTS 5.1.2 Bottom Housing
12 13 14
24
15
22
19
17
23
18
21
16 20
Figure 5-2. Bottom Housing. 5-4
CHAPTER 5 DRAWINGS AND PARTS LISTS TABLE 5-2. SPARE PARTS LIST BOTTOM HOUSING Item Description 12 Seal for housing top
Part Number 11113362
13
Weighing cell incl. EEPROM (Item 18) and seal
11113850
14
Seal for weighing cell
11600363
15
Power supply board
11113780
16
U board
11113853
17
Battery 3 V, Lithium, CR 2032 or equivalent
18
Cell EEPROM 1)
11103757+SNR
19
Cable U – power supply
11113773
20
Bottom housing
11113350
21
Leveling screw
11101302
22
Level
11101335
23
Microfuse cap (fuse T6,3 A/250 V)
89290
24
Line cable (accessory)
6569-00, 120V US
24
Line cable (accessory)
76212-00, 220V EU
24
Line cable (accessory)
76448-00, 240V UK
24
Line cable (accessory)
76199-01, 240V AUS
See Note
1) The order has to contain the serial number SNR of the balance! NOTE: battery is not available as a replacement part. Must source locally.
5-5
CHAPTER 5 DRAWINGS AND PARTS LISTS 5.1.3 Dryer Unit
25
36 26
27
28 32 29
30
33
35 34
Figure 5-3. Dryer Unit.
5-6
CHAPTER 5 DRAWINGS AND PARTS LISTS TABLE 5-3. SPARE PARTS LIST DRYER UNIT Item
Description
Part Number
25
Reflector
214382
26
Protective glass
214360
27
Halogen radiator110V Halogen radiator 230V
214417 214418
28
Heating module110V Heating module 230V
11113500 11113501
29
Temperature sensor
214349
30
Thermal overload device
214698
32
Dryer unit
11113555
33
Dryer unit hinge left
11600358
34
Dryer unit hinge right
11600357
35
Dryer unit cable
11113771
36
Dryer unit cover
11113503
5-7
CHAPTER 5 DRAWINGS AND PARTS LISTS
5-8
APPENDIX A SOFTWARE SERVICE TOOL INSTRUCTIONS A.
SERVICE NOTES
A.1 Software Service Tool Instructions This software tool is used when a new Main PCB is installed to: 1. Configure the Main PCB. 2. Enter balance serial number 3. Install the application software
SOFTWARE LEGEND MB45 GLOBAL 11670614x.MOT MODEL WHERE USED SOFTWARE FILE REVISION
A.2 Requirements 1. File: MB45 Service Tool Install.zip 2. Application Software File: a. MB45 Global 11670614x.mot b. MB35 Europe 11670806x.mot c. MB35 Latin America 802509712.mot d. MB35 US 11670787x.mot 3. A PC running Windows 95 to XP 4. Interface cable Ohaus part number 80500525 (Serial extension cable)
A.3 Instructions and Notes 1. To open click on the zip file 2. Find the setup file (Setup.exe) and click on it. 3. Follow the instructions. 4. Copy the application software file to the desktop. This is not required but will make the file easier to find later. 5. It is advisable to hook up the balance to HyperTerminal and make sure it is communicating. You will need a standard 9 pin serial extension cable, Ohaus part number 80500525 to connect to your PC. 6. Find “MB45 Service Tool” in the program files and click it to start. 7. The screen below will open.
8. Match the serial port parameters to the balance. Balance defaults are shown above. 9. Click on the tab “Main Board Replacement”
A-1
APPENDIX A SOFTWARE SERVICE TOOL INSTRUCTIONS
10. Click on the button that matches the balance. 11. Enter the serial number of the balance. 12. Enter the TDNR number of the balance. Note: The serial number and TDNR number are printed on a label on the back of the balance. 13. CAUTION – Confirm the information entered above. This programming can only be done once. If you have made and error, click the button “Abort Data Entry” then reenter the data. 14. When the above information has been confirmed click the “Start” button. The following screen will open to indicate the new main board has been configured.
15. Click on the “” Tab. 16. Browse to the required Application Software file (mot file).
A-2
APPENDIX A SOFTWARE SERVICE TOOL INSTRUCTIONS 17. Press the start button.
18. If there is a problem press the red button a. The red button is intended to the data for the very first time or to a blank EEPROM. It is also intended to be used as a last resort if the start button fails. b. Using the start button will save the existing ’s test library, using the red button will not. c. After the red button is clicked you will see a screen that says “Please cycle power to scale…”. At this time unplug the scale from the AC line for about 30 seconds and plug it back in. The will then take about 3 minutes. When it is complete the message “File is SUCCESSFUL”(Checksum=xxxxxxx) will be displayed. If the message “Application code has FAILED” is shown click the OK button and click the red button again. The second time it should work.
A-3
APPENDIX A SOFTWARE SERVICE TOOL INSTRUCTIONS When the software has been ed the following screen will be shown.
A.4 Error Messages
Indicates the computer can not establish a connection to the balance.
Indicates the main board has already been configured. A main board can be configured only once and can not be reconfigured.
Indicates the TDNR number does not match the balance configuration selected. Click “Abort Data Entry” then re-enter the correct data.
A-4
MB45 MOISTURE ANALYZER
SERVICE MANUAL P/N 80250897 A
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