Trooper® Scale & Trooper® Count Scale
Contents
1. 4 6 4 3 Trooper Scale EAR rel 4 8 4 4 Trooper Count Scale 5292 CommondsS gidd 4 9 5 1 Trooper Scale TR and Trooper Count Scale TC Parts List 5 3 1 Trooper Scale Linearity Le TEE A 4 A 2 Trooper Count Scale Linearity Weights Rentas A 4 LIST OF ILLUSTRATIONS FIGURE NO TITLE PAGE 2 Trooper Scale Interconnection 2 7 2 2 Trooper Scale Membrane Switch Wiring Diagram 2 7 2 3 Trooper Count Scale Interconnection Diagram 2 17 2 4 Trooper Count Scale Membrane Switch Wiring Diagram 2 18 3 Trooper Scale Connector LEES 3 2 3 2 Trooper Scale RS Connector and Loadcell Connector Wiring 3 3 3 3 Trooper Scale Component LoGGIOfIS ege 3 5 3 4 Trooper Count Scale Main PC Board Connector Locations 3 7 3 5 Trooper Count Scale RS Connector Loadcell Connector Wiring 3 8 3 6 Trooper Count Scale Component Locations 3 10 4 Trooper Scale Segment Displays EE 4 1 4 2 Trooper Count Scale Segment 4 1 4 3 Standard Deviation 4 3 4 4 Calculation of Standard 3 2022. Reading Weight kg Weight Mean Weight Mean 1 2 3 4 5 6 7 8 9 10 SUM SUM Mean SUM 10 Variance SUM 9 Mean O Variance o Figure 4 4 Calculation of Standard Deviation Reading Weight kg Weight Mean Weight Mean 1 3 4 2 3 4 3 3 4 4 3 4 5 3 4 6 3 4 7 3 4 8 3 4 9 3 4 10 3 4 SUM 1 SUM 5 Mean SUM 10 Variance SUM 9 6 Mean 2 Variance 7 After recording the ten weight readings in the Weight column perform the following steps 0 01400 Record the sum of the ten weight readings here Record the Mean Avg of the ten weight readings here SUM divided by 10 For each weight reading subtract the calculated Mean and record the result For each weight reading record the square of the Weight Mean from step 3 Record the sum of the squared Weight Mean values from step 4 Record the Variance of the ten weight readings here SUM divided by 9 Record the Standard Deviation of the ten weight readings here square root of the Variance 4 3 CHAPTER 4 TESTING 4 3 1 Repeatability Test Cont Figure 4 5 Sample Calculation of Standard Deviation O Reading Weight kg Weight Mean Weight Mean 1 3000 0 02 0004 2 3000 0 02 0004 3 3000 2 18 0324 4 3000 0 02 0004 5 3000 2 18 0324 6 30
3. 4 3 FIGURE NO 4 5 4 6 4 7 5 1 LIST OF ILLUSTRATIONS Cont TITLE PAGE Sample Calculation of Standard Deviation 4 4 Off Center Load Test Weight Locations 22 2 4 4 5232 Interface Connections sacan ea ttu dtt 4 8 Expoded View of Trooper Scale and Trooper Count Scale CHAPTER 1 INTRODUCTION 1 INTRODUCTION This service manual contains instructions for the repair and maintenance work to be performed by Ohaus Dealers or Ohaus authorized service centers Knowledge of the operation of the Scale is assumed Instruction manuals are included with this service manual For complete information on operation refer to the Instruction Manual This manual covers maintenance on the following Trooper Scales capacities 3kg 6kg 15kg and 30kg Trooper Count Scales capacities 3kg 6kg 15kg and 30kg The contents of this manual are contained in five chapters and an Appendix with calibration information Chapter 1 Introduction Contains information about service facilities tools and test equipment test masses and service strategy Chapter 2 Diagnosis Contains information on problem verification scale examination preliminary checks troubleshooting tables interconnection diagrams and wiring diagrams Chapter 3 Repair Procedures Contains detailed repair procedures for all major components Chapter 4 Testing Contains performance tests specifications and commu
4. BaudRate Lock Setup CalUni Parity Lock Read Span Point Data Lock Print Beeper On Stable Cal Full Lock Library Auto Off Header Cal Half Lib Enable Part No Span Pieces Span Count ACC PCS Span Auto Add Unit Gram Auto Optimiz Unit Kg Print Clear Unit Lb Tare M Requires Unit Oz Gross AutoZero OHAUS Update TROOPER COUNT Configurable parameters are highlighted in blue text on screen and are described as follows Model Fixed model selections are available TC3RS TC6RS TC15RS TC3ORS Selecting model automatically loads the associated default scale Personality Setup and Menu Setup parameters Serial No Up to 6 digit serial number of the Trooper Count Scale is entered in this field Metric Unit Setting Selecting the Metric Unit Setting deactivates non metric units from the screen and from the scale non metric units are not visible in the scale menus To select click on the Only Metric field check mark will appear in the box then click on the Change button To de select click onthe Only Metric field to remove the check markthen click on the Change button B 2 APPENDIX B TROOPER COUNT SCALE TOOLS e Print Headers User defined Printer Headers can be entered in the fields Line 1 and Line 2 up to 15 characters each After entering the Printer Headers click on the Update
5. MR COUNT 55 gt M 7 PCS COUNT Enter Place the indicated calibration mass on the pan Press the Enter button The sample illustration indicates a 6kg Scale using a 4kg mass for the first linearity entry Scale is determining first linearity value WEIGHT DATA LHL hund kg A 2 g Net APW MR M 5 gt 5 APPENDIX A CALIBRATION 2 TROOPER COUNT SCALE LINEARITY CALIBRATION Cont WEIGHT DATA COUNT PLAL then kg g oz Net B G PT MR M gt COUNT COUNT 55 Enter Place the indicated calibration mass on the pan Press the Enter button The sample illustration indicates 6kg Scale using 6kg mass Scale is determining second linearity value If the calibration was successful LIN TEST DONE is displayed momentarily followed by CAL MENU and the calibration data is saved Kj s automatically Remove calibration masses from pan WEIGHT DATA rl FECE amm c m LHL buhy VI noct LIIL J IE HL To return to weighing press the Data button A 3 APPENDIX CALIBRATION A 3 LINEARITY CALIBRATION WEIGHTS Linearity calibration weights are defined in Tables A1 and A 2 for the Trooper Scale and Trooper
6. OHAUS TROOPER SCALE amp TROOPER COUNT SCALE SERVICE MANUAL Ohaus Corporation 19A Chapin Road Box 2033 Pine Brook NJ 07058 973 377 9000 9 OHAUS Trooper Scale amp Trooper Count Scale SERVICE MANUAL TROOPER SCALE TROOPER COUNT SCALE 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 2004 Ohaus Corporation all rights reserved Registered trademark of Ohaus Corporation TABLE CONTENTS CHAPTER 1 INTRODUCTION Page kh dl rre 1 1 IEEE 000 le EE 1 1 UE Eidel tele uh xar ra dM 1 2 1 2 1 Standard Tools and Test 1 2 122 00 2 EP 1 2 1 9 Calibration Masses Required EE 1 2 lA TT 1 3 CHAPTER 2 DIAGNOSIS 2 M M 24248 2 1 2 1 08 3000 2 1 2 2 Cn URS 2 1 2 3 Troubleshooting Tables 2 1 2A 1 08018 01 geed 2 7 2 5 Trooper S
7. 4 7 4 6 1 Setting Trooper Scale Print Men 222 2 44 4 7 4 6 2 Setting Trooper Count Scale Print 4 4 7 4 6 3 Connecting ING RS232 4 8 4 6 4 Print 4 9 TABLE OF CONTENTS Cont CHAPTER 5 PARTS LISTS Page 5 POMS SIS c 5 1 5 1 Trooper Scale Trooper Count Scale Exploded 5 2 APPENDIX A CALIBRATION A 1 Trooper Scale Linearity Calibration 22877775 77777977 A 1 2 Trooper Count Scale Linearity Calibration 2 A 2 Peo 93 4 APPENDIX TROOPER COUNT SCALE TOOLS 11 12 11 TEE 1 B2 11 11 1 5 1 B2 Minimum Requirements data ees 1 B22 Connecting the RS232 Interface geste et pae bud 1 B 2 3 Installing the Trooper Count Scale Tools Software Program 1 B 2 4 Opening the Trooper Count Scale Tools Software Program 1 EE 2 5259 Configuration 2 B 32a a A 4 Bo WEST CORIO 7 2252 DONO EE
8. FERRITE CORE LOAD CELL LFT LOCK SWITCH RS232 CABLE BATTERY BOX LOAD CELL amp CABLE POWER CONNECTOR CABLES PC BOARD MEMBRANE SWITCH CONNECTOR LCD DISPLAY Figure 3 3 Trooper Scale Component Locations 3 5 CHAPTER 3 REPAIR PROCEDURES 3 4 REPLACING THE TROOPER COUNT SCALE MEMBRANE SWITCH The membrane switch is affixed to the upper housing ofthe scale The scale must be disassembled to gain access to the membrane switch connections 1 2 Remove power from the scale Carefully lift and remove the platform from the scale One rubber foot remains attached to the platform This ensures the platform is properly located on the weighing load cell Turn fhe scale over and remove the six screws which hold the upper housing One screw is located underneath the rear most sealing cover The cover screw will have to be removed first CAUTION Use care in the next step as the membrane switch wiring is attached to the PC board Place the scale upright position and carefully lift the upper housing from the bottom housing about two to three inches Reach under the upper housing from the front and carefully disconnect the three flexible cables from the Main PC board Two cables are part of the membrane switches and the other cable is for the display PC board On upper housing lift up the defective membrane switch if necessary carefully prying it up with a knife and gently peel it off the uppe
9. G N T amp MENU PRINT UNITS COMM NOT USED Figure 2 1 Trooper Scale Interconnection Diagram 1 2 MEMBRANE 3 SWITCH 4 5 Figure 2 2 Trooper Scale Membrane Switch Wiring Diagram 2 1 CHAPTER 2 DIAGNOSIS 2 5 TROOPER SCALE ERROR CODE TABLE The Trooper Scale is equipped with software which will display an error condition when it occurs Review the listed codes and follow instructions to correct the problem TABLE 2 7 TROOPER SCALE ERROR CODES ERROR CODE CAUSE REMEDY LoBat Batteries are weak Replace batteries Error 1 The load on the platform ex Remove excess load ceeds the rated capacity Check load cell connections ihe scale overload condi Refer to the Troubleshooting Tables tion Error 2 Underload condition Press the ON ZERO Off button If the load cell signal is morethan problem persists refer to the trouble 9 divisions below zero shooting section to check the load cell assembly Error 7 EEPROM data incorrect Turn scale on and off and on again error 7 remains replace the Main PC board Repair Procedures 3 2 Error 14 When ZERO button is Enterthe Setup Menu and set the zero 90 pressed the load onthe pan 10 a higher setting See Instruction exceeds zero 96 menu set Manual ting Could be caused by a load on fhe pan At power up the load cell Perform a linearity calibration If this signal is outside the all
10. meter measure the resistance between pins 1 to all other pins on the mem brane switch cable they should all be open then press each button and check that the resistance is zero for each button If continuity is not present the membrane switch is de fective Replace Membrane Switch Repair Procedures 3 1 or Substitute with a good membrane switch plugged into the Main PC Board and press each button if they work the original Membrane Switch is de fective and should be replaced gt Repair Procedures 3 1 If Membrane Switches OK re place Main PC Board gt Repair Procedures 3 2 2 3 CHAPTER 2 DIAGNOSIS TABLE 2 4 TROOPER SCALE NO DISPLAY OR PARTIAL DISPLAY SYMPTOM PROBABLE CAUSE REMEDY Display is on or partial characters are displayed Main PC Board is defective The Main PC Board is replaced as a whole assembly Check procedures in Table 2 1 first and verify that other prob lems do not exist Replace Main PC Board Procedures 3 2 gt Repair TABLE 2 5 TROOPER SCALE CANNOT CALIBRATE SYMPTOM PROBABLE CAUSE REMEDY Scale can be turned on but will not calibrate Incorrect weights LFT lock switch is in the locked position and or The software lock menu is set to ON LCL On Load cell assembly defec tive Verify that proper weights are used Set LFT lock switch to unlocked posi tion and
11. PROBABLE CAUSE REMEDY Scale does not respond to front panel controls NOTE Use a known good ac adopter for this test Membrane switch defective 1 N Open the scale remove six screws from the bottom of the scale Refer to Figure 2 4 Using an Ohm meter measure the resistance on all switches on the membrane switch cable they should all be open then press each button and check that the resistance is zero for each button If continuity is not present the mem brane switch is defective Replace membrane Switch gt Repair proce dures 3 4 Or Substitute with a good membrane switch plugged into the Main PC board and press each button if they work the original membrane switch is de fective and should be replaced gt Repair procedures 3 4 If the membrane switch is OK re place the Main PC Board gt Repair procedures 3 5 2 11 CHAPTER 2 DIAGNOSIS TABLE 2 11 TROOPER COUNT SCALE NO DISPLAY OR PARTIAL DISPLAY SYMPTOM PROBABLE CAUSE REMEDY Display is not on or partial characters are displayed Eitherthe display board con nector is loose from the Main PC board or the display PC board is defective Main PC board is defective Remove the 6 screws from the bottom cover of the scale carefully remove the platform top cover and remove the three flexible cables from the Main PC board Check thatthe cable connectors were not loose The displa
12. 2 Standard Electronics tool kit 3 Desk magnifier on a stand 4 Grounding mat and clip b Flat Exacto blades and holder 1 2 2 Special Tools To service the Ohaus Trooper Scale and Trooper Count Scale the following equipment is recommended APC computer with a terminal program for communications Trooper Count Scale Tools software program Ohaus P N 80500590 RS 232 Cable Ohaus P N 80500433 9 pin or standard null modem cable RS 232 Cable Ohaus P N 80500431 IBM PC 25 Pin Ohaus Printer Model SF42 Ohaus Printer Cable P N 80500571 AC adapter 120V 60Hz US Ohaus P N 80500435 AC adapter 230V 50Hz EU Ohaus P N 80500436 AC adapter 230V 50Hz UK Ohaus P N 80500437 AC adapter 240V 50 Hz AU Ohaus P N 80500462 Load Cell Simulator 1 3 CALIBRATION MASSES REQUIRED The masses required to test the Ohaus Trooper Scale and Trooper Count Scale must meet the requirements of ASTM Class 4 or OIML F2 The mass values are listed in Table 1 1 Bolded values are default settings TABLE 1 1 CALIBRATION MASSES TROOPER COUNT SCALE TROOPER SCALE Span Cal choices Linearity Cal fixed ra kg Masses a Masses ED 515 TRI5RS TC30RS TR30RS Linearity Cal fixed Masses Totaling TC3RS TC6RS TR6RS 5 10 15 Ib 10 amp 15 Ib TC15RS TRISRS 10 20 30 Ib 20 amp 30 Ib TC30RS TR30RS 20 40 60 Ib 40 amp 60 Ib CHAP
13. 8 53 01 11 9 TABLE OF CONTENTS Cont LIST OF TABLES TABLE NO TITLE PAGE 1 1 Calibration MUSSOS 1 2 2 1 Trooper Scale Will Not Turn on With AC 2 1 2 2 Trooper Scale Will Not Turn on Using Batteries 2 2 2 3 Trooper Scale Does Not Respond to Front Panel Controls 2 3 2 4 Trooper Scale No Display or Partial Display 2 4 2 5 Trooper Scale luet ele EE 2 4 2 6 Trooper Scale Communications Failure 2 6 2 7 Trooper Scale EOE 00651241 PE 2 8 2 8 Trooper Count Scale Will Not Turn on With AC Adapter 2 9 2 9 Trooper Count Scale Will Not Turn on Using Batteries 2 10 2 10 Trooper Count Scale Does Not Respond to Front Panel Controls 2 11 2 11 Trooper Count Scale No Display or Partial 2 12 2 12 Trooper Count Scale Cannot Calibrate 2 13 2 13 Trooper Count Scale Communications 2 14 2 14 Trooper Count Scale Error Codes EE 2 15 4 1 Trooper tii aes EE dabat ba iua 4 6 4 2 Trooper Count Scale Specifications
14. The Linearity test is used to determine the linearity of the scale throughout its operating range NOTE The scale must pass the Repeatability and Off Center Load Tests before the Linearity test is performed Before performing this test calibrate the scale according to Appendix A Place masses totaling 1 3 of the capacity of the scale on the platform and note the weight Set this mass aside it will become the test mass Place masses totaling 1 3 of the capacity of the balance on the platform and zero the scale Place the test mass on the platform and record the weight Place masses totaling 2 3 of the capacity of the scale on the platform and zero the scale Place the test mass on the platform and record the weight The difference of the 3 recorded weights should be less than or equal to the tolerance values listed in tables 4 1 and 4 2 4 5 CHAPTER 4 TESTING 4 4 TROOPER SCALE SPECIFICATIONS TABLE 4 1 TROOPER SCALE SPECIFICATIONS Model TR3RS mees TRISRS TR3ORS Default Capacity X Readability Ib X 0 0TIb Default Capacity X Readability kg 30kg X 0 005kg Default Capacity X Readability 30000g X 5g Default Capacity X Readability 02 48002 0 1027 96007 X 0 207 Type Approved Capacity X Readability Ib 60 0 0210 Type Approved Capacity X Readability kg 30kg X 0 01kg Type Approved Capacity X Readability g 30000g X 10g Type Approved Capacity X Readability oz 48007
15. removing all traces of adhesive The best method is to use a flat razor blade Insert the cable from the new membrane switch through the hole in the upper housing Peel off the protective film from the new membrane switch and carefully align and affix to the upper housing Press the membrane switch down uniformly Using your fingers with a cloth roll from the center of the membrane switch outward towards the edges to remove any air bubbles that may be trapped Position the upper housing in place over the scale and connect the flexible cable from the membrane switch to socket J5A on the Main PC board 10 Reassemble the scale by replacing the six screws at the bottom of the scale which secure the upper housing 11 Replace the platform on top of the scale 3 1 CHAPTER 3 REPAIR PROCEDURES 3 2 REPLACING THE TROOPER SCALE MAIN PC BOARD The Main PC Board is located inside the scale towards the front To replace the Main PC Board it is necessary to disassemble the scale 1 Perform steps 1 through 4 of paragraph 3 1 2 Remove the connector plugs from J6 and J7 on the Main PC Board which is battery and external power See Figure 3 1 YES TO LOADCELL LFTLOCK TO RS232 JUMP 2 SWITCH LOCKED ON POSITION ii sl ss 0 00090001 Wi JUMP 2 me BATTERY EXTERNAL POWER TO MEMBRANE SWITCH Figure 3 1 Trooper Scale Connector
16. Count Scale TABLE A 1 TROOPER SCALE LINEARITY WEIGHTS Linearity cal fixed Masses Totaling Linearity cal fixed Bill _ TR3RS 4 86 0 TRERS 10 amp 15 Ib TRI5RS 20 amp 30 Ib TR30RS 40 amp 60 Ib TABLE A 2 TROOPER COUNT SCALE LINEARITY WEIGHTS Linearity Cal fixed Masses Totaling TC30RS 40 amp 60 Ib NOTE Recommended tolerance Class for the calibration masses ASTM Class 4 or OIML F2 A4 APPENDIX B TROOPER COUNT SCALE TOOLS 1 INTRODUCTION This Appendix covers the use of the Trooper Count Scale Tools software from Ohaus Corporation Trooper Count Scale Tools is a maintenance software program designed to work with the Trooper Count Scale Through the RS232 interface this program allows a user to configure the scale settings and library data and test output commands from a PC Use of the Trooper Count Scale Tools is required after the main PC board of the Trooper Count Scale is replaced B 2 INSTALLATION B 2 1 Minimum Requirements The following are minimum requirements for installing and using Trooper Count Scale Tools Ohaus Trooper Count Scale with standard RS232 serial port Ohaus compatible Serial Cable Ohaus part number 80500433 or 80500431 PC or compatible Pentium 75Mhz or better Windows 95 98 NT or 2000 b MB of free hard disk space B 2 2 Connecting the RS232 Interface Connect the Serial Cable between the RS232 serial port of the Trooper Count Scale
17. J3 on the Main PC board and the single cable from the display PC board to connector J4 on the Main PC board Reassemble the scale Replace the platform on top of the scale After installation check all operations if possible set the original customer settings back into the scale and calibrate the scale 3 7 REPLACING THE TROOPER COUNT SCALE LOAD CELL ASSEMBLY The Load Cell Assembly is centrally located inside the scale See Figure 3 6 The Load Cell is factory assembled and the downstops are preadjusted There are no adjustments to be made on this assembly after installation 1 2 Perform steps 1 through 4 of paragraph 3 4 Disconnect cable connector from J10 which is connected to the Load Cell See Figure 3 5 for wire color and locations Remove the four screws holding the Load Cell Assembly to the bottom housing Lift the Load Cell Assembly out of the bottom housing and replace with a new one Connect cable from the Load Cell to connector J10 Position the upper housing in place over the scale and connect the flexible cables from the membrane switch to connectors J2 J3 and the cable from the display PC board to connector J4 on the Main PC board Check the LFT lock switch switch Make sure it is in the ON position on the scale When self testing is completed the display may indicate an error code This is normal Do not turn off the power Switch zie switch to its OFF position CHAPTER 3 RE
18. Perform steps 1 through 4 of section 3 4 2 Remove the connector plugs from connectors J7 J8 and J10 from the Main PC Board which is the battery external power wires and Load Cell See Figure 3 4 LFT LOCK SWITCH TO BATTERY TO LOAD CELL 00000 EXTERNAL POWER 5 232 TO MEMBRANE SWITCH Figure 3 4 Trooper Count Scale Main PC Board Connector Locations 3 Carefully remove the wires coming from J6 which is the RS232 connector See Figure 3 5 for wire color and locations 4 Remove the four corner screws on the Main PC Board 5 Replace the Main PC Board and install the four screws previously removed 6 Replace the color coded wiring for connector J6 Check color coded wiring is correctly installed 7 Replace the connectors to J7 J8 and J10 on the Main PC Board 8 Position the upper housing in place over the scale and connect the flexible cables from the membrane switch to connectors J2 J3 on the Main PC board and the cable from the display PC board to connector 9 Check that the LFT lock switch is in the unlocked position 3 7 CHAPTER 3 REPAIR PROCEDURES 3 5 REPLACING THE TROOPER COUNT SCALE MAIN PC BOARD Cont TO LOAD CELL SHIELD ORANGE BLACK GREE TO BATTERY WHITE N RED Figure 3 5 Trooper Count Scale RS Connector and Loadcell Connector Wiring 10 After the scale is tu
19. and the serial port of the computer Note which serial port of the computer i e 1 2 etc the cable was connected as this information may be required when configuring the software B 2 3 Installing the Trooper Count Scale Tools Software Program With the Trooper Count Scale Tools CD on hand e Load the CD containing the Trooper Count Scale Tools software program onto the computer e Open the CD directory folder e Select Setup to install the program e Follow the installation instruction as they appear on screen B 2 4 Opening the Trooper Count Scale Tools Software Program Select the TC Tools application icon located in the program destination folder specified during installation With a functional RS232 connection TC Tools automatically sets up the communication parameters these settings can be manually set up in the COM Port screen Subsequent to accepting the End user License Agreement during program start up the first screen Config appears There are 4 screens available e Configuration Config e Library e Test Command e COM Port Refer to the following sections for applicable screen operations 1 APPENDIX B TROOPER COUNT SCALE TOOLS B 3 SCREEN OPERATIONS B 3 1 Configuration Config The Configuration Screen allows the user to modify scale model data and setup parameters OHAUS Trooper Count Tools 2 7 Capacity Lock Count Back Light Format 1585 2 Lock Switches Setup Print 12345 Lock
20. board is defective and should be replaced Re place Membrane Switch gt Repair Pro cedures 3 4 2 9 CHAPTER 2 DIAGNOSIS TABLE 2 9 TROOPER COUNT SCALE WILL NOT TURN ON USING BATTERIES SYMPTOM PROBABLE CAUSE REMEDY Scale will not turn on with new batteries installed Incorrect battery installation Wiring harness defective or battery clips connection bro ken Membrane switch defective Main PC Board is defective Check position of batteries Remove the 6 screws from the bottom cover of the scale carefully remove the platform top cover and remove the flex ible cable from the Main PC board Check dc voltage at pins 1 and 3 of connector J7 on the Main PC board See Figure 2 3 Voltage should read approxi mately 9 Volts dc If voltage is not present atthe connector remove the batteries and make a continuity test between each of the connectors in the battery box to con nector J7 pins 1 and 3 on the Main PC board Resistance should be 0 ohms for the red lead and ohms for the black lead If an open condition exists trace wiring and resolder or replace wiring as necessary If OK proceed See Table 2 10 If the scale fails to turn on with a new membrane switch the Main PC board is defective and should be replaced Repair Procedures 3 5 2 10 CHAPTER 2 DIAGNOSIS TABLE 2 10 TROOPER COUNT SCALE DOES NOT RESPOND TO FRONT PANEL CONTROLS SYMPTOM
21. button to save the text into the scale Do Calibration after Config Selecting this option box is checked off automatically initiates Linearity Calibration procedures when Configuration parameters are ready to be transferred to the scale Write Config Data to Scale button is selected Make sure appropriate calibration weights are available at this time After transferring data to the scale select OK from the following acknowledgement screen Follow subsequent calibration instructions accordingly Calibration Other Configuration Screen items are described as follows Personality Setup and Menu Setup These setup parameters designate scale model and menu mode settings and are automati cally updated based on the Model and Metric Unit Setting selected Sub menu items cannot be configured manually by the user Read Config Data from Scale Button Select this button to load and display the configuration data from the scale into the Trooper Count Scale Tools program Write Config Data to Scale Button Select this button to transfer the configuration data from the computer to the scale The transfer is acknowledged on screen as follows if the Do Calibration after Config setting was not selected Configuration eu cem B 3 APPENDIX B TROOPER COUNT SCALE TOOLS B 3 2 Library The Library Screen offers a method to quickly and conveniently read enter and save individual Library records OHAUS
22. or Set the software lock menu to OFF LCLOFF then refer to instruction manual Remove the 6 screws from the bottom cover ofthe scale Carefully remove the platform Lift the top cover and lay aside leaving the cables connected to the Main PC Board With the scale plugged in and turned on measure voltage on terminals EXE and The nominal voltage should be 5 V dc If the voltage is much lower disconnect the load cell from the PC Board and measure again If 5V dc is present the load cell may be shorted and requires replacement Continue see next page 2 4 CHAPTER 2 DIAGNOSIS TABLE 2 5 TROOPER SCALE CANNOT CALIBRATE Cont SYMPTOM PROBABLE CAUSE REMEDY Scale can be turned on but will Load Cell assembly defec not calibrate Cont tive Main PC Board defective With the platform in place and the scale on measure across pins SIG and SIG on the PC Board Typical no load output from the Load Cell is 1 0 mv to 1 0 mv If the output exceeds this value replace the load cell If this measurement is within limits place a full load on the platform and measure again The difference between zero and full load readings should be as shown in the table below If the reading is out of this range try replac ing the Load Cell gt Repair Procedures 3 3 NOTE Readings may differ from table due to load cell tolerances Reassemble the scale perform tests in Se
23. reflect that the operation was executed T Tare Taresthe scale similarto pressing the TARE button from the scale A result of OK on screen confirms the operation The scale will also reflect that the operation was executed V Get Version Number Displays the model and software version of the Trooper Count Scale on the Response from scale field B 7 APPENDIX B TROOPER COUNT SCALE TOOLS B 3 4 COM PORT The COM Port Screen allows the user to automatically set up 85232 connections or manually specify scale print settings to establish proper communications Sr Config port C Automatic Setup Manual Setup Set these to match the scale Print Menu settings Baud Rate Data Bits EH Automatic Setup is the default setting The following scale Print Menu settings can be specified when selecting Manual Setup bolded selections are default settings Port Available selections are COMI COM2 COM3 or Baud Rate Available selections are 1200 2400 4800 9600 or 19200 Data Bits Available selections are 7 or 8 Parity Available selections are None Even or Odd B 8 APPENDIX B TROOPER COUNT SCALE TOOLS B 4 TROUBLESHOOTING Several Error screens may appear due to conditions listed as follows e Communication Error The following error message appears when a communication error between the scale and the computer is detected Check and remedy the appropriate connections and
24. screen into a user designated file Specify the destination directory folder and file name as prompted on the following Save As screen Keep the Save as Type field blank Then select Save to execute the process Local Disk E My Documents h Mu Computer My Network P APPENDIX B TROOPER COUNT SCALE TOOLS B 3 3 Test Command The Test Command Screen enables the user to send type in a test command from the computer keyboard and log the data output on screen Most commands mimic the button functions of the scale OHAUS Trooper Count Tools 2 7 oy 0 0 0 00000 kg 0 520 kg Sr2 7 Initiate use of the Test Command screen by selecting the Connect button first to establish connection between the scale and the computer Note A communication error message will appear if connection cannot be established refer to Sections B 4 Troubleshooting and B 3 4 COM Port Screen for further details Type in a test command followed by the Enter key test commands are case sensitive use upper case letters only The available Test Commands are listed and described as follows for examples referto Test Command Screen P Print Displays the print data output of the scale on the Response from scale field Z Zero Zeroes the scale similar to pressing the ON ZERO Off button from the scale A result of OK on screen confirms the operation The scale will also
25. the platform in place and the scale turned on measure across pins SIG and 4516 on the Main PC Board Typical no load output from the load cell is 1 0 mv to 1 0 mv If the output exceeds this value replace the load cell If this measurement is within limits place a full load on the platform and measure again The difference between zero and full load reading should be as shown on the table on the next page the reading is out of this range replace the Load Cell gt Repair Procedures 3 7 NOTE Readings may differ from table due to load cell tolerances Reassemble the scale perform tests in Section 5 and verify operation 2 13 CHAPTER 2 DIAGNOSIS TABLE 2 12 TROOPER COUNT SCALE CANNOT CALIBRATE Cont SYMPTOM PROBABLE CAUSE REMEDY Scale can be turned on but will not calibrate Main PC Board is defective If the above readings are within limits the Main PC Board is defective To check the Main PC Board if unsure about the load cell connect a known good load cell or load cell simulator to connector as shown in Figure 2 3 Use an output of O mv V for CAL ZERO and 1 mv V for span calibration unable to calibrate the Main PC Board is defective Replace the Main PC Board gt Repair Procedures 3 5 LOAD CELL OUTPUT READINGS NOTE MODEL SPAN SIGNAL TC3RS 4 0 5 0mv TC6RS 3 5 4 5mv 1585 4 5 5 5mv TC30RS 6 5 8 3mv Span signal readings are appr
26. 00 0 02 0004 7 2999 8 22 0484 8 3000 0 02 0004 9 3000 0 02 0004 10 3000 0 02 0004 SUM 30 000 2 SUM 0 116 Mean SUM 10 Variance SUM 9 0129 Mean 3000 02 Variance o 0 114 4 3 2 Off Center Load Test The Off Center Load Test is used to determine whether displayed weight values will be affected by moving the load to different areas of the weighing pan See Figure 4 6 MASS LOCATIONS Figure 4 6 Off Center Load Test Weight Locations 4 4 CHAPTER 4 TESTING 4 3 2 Off Center Load Test Cont 1 2 Zero the scale Place a test weight equal to 1 2 the scale capacity in the center of the weighing platform and record the reading Move the test weight to the mid point between the center and the left edge of the weighing platform and record the reading Move the test weight to the mid point between the center and the rear of the weighing platform and record the reading Move the test weight to the mid point between the center and the right edge of the weighing platform and record the reading Move the test weight to the mid point between the center and the front of the weighing platform and record the reading Subtract the center position reading from the reading at each outer position The difference at each test position should be within the cornerload tolerance specified in Table 4 1 for Trooper Scale and Table 4 2 for Trooper Count Scale 4 3 3 Linearity Test
27. 232 Interface Connect the RS 232 cable from the Scale to the Computer When the interface is connected to a computer two way communication between the computer and scale is possible using the commands outlined in the 85232 Command Table 4 3 for Trooper Scale and Table 4 4 for Trooper Count Scale See Figure 4 7 for connections When the scale is connected directly to a printer displayed data can be output at any time by simply pressing PRINT UNITS button on the Trooper Scale and Trooper Count Scale N C Data In RXD Data Out TXD 5 0 3 D N C 9 8 0 6 Ground N C FRONT VIEW OF N C SCALE CONNECTOR N C N C 1 2 3 4 5 6 7 8 9 Figure 4 7 85232 Interface Pin Connections RS232 Commands All communication is accomplished using standard ASCII format Only the characters shown in the 185232 Command Table 4 3 and 4 4 are acknowledged by the scale Invalid command response ES error indicates the scale has not recogonized the command Commands sent to the scale must be terminated with carriage return and line feed CRLF Data output by the scale is always terminated with a carriage return and line feed CRLF TABLE 4 3 TROOPER SCALE RS232 COMMANDS Command Character Description Print current mode kg g oz Same as pressing PRINT button Same as pressing TARE button Same as pressing ZERO button Print Stable only Where 0 Off and x 1 On Automatically send data when stable after motion Sen
28. 60Hz AU 1 5 4 TROOPER SCALE LINEARITY CALIBRATION APPENDIX A CALIBRATION If required turn the Calibration Lock Switch off With the Scale ON press and hold the button 1l G N T MENU until MENU is displayed When you 2 release the G N T MENU button CAL is displayed d H H Press G N T MENU button SPAN Y is displayed Press PRINT UNITS button Lin Y is displayed Press G N T MENU button C is displayed The scale MUST be stable during this period and is establishing a zero point After a few seconds the display flashes LIN CP twice and the requested ro weight value is displayed The sample illustration LJ indicates a 4kg mid pointfor a 6kg scale Linearity calibration for Trooper is O 2 3 and full capacity LI d kg Place the indicated mass on the platform Keep the platform stable during this period Press G N T MENU button C is displayed The scale MUST be stable during this period and is establishing the intermediate point After a few seconds the display flashes FULLCP and the re quested weight value is displayed e Place the indicated mass on the platform and press the G N T MENU button C is displayed The scale MUST be stable during this period and is establish ing the full scale point If linearity calibration was successful the calibra tion mass is displayed and the calibration data is b Intr saved automatically If unsuccessful refer to t
29. 7 TROOPER COUNT ERROR CODE TABLE TABLE 2 14 TROOPER COUNT SCALE ERROR CODES ERROR CODE CAUSE REMEDY lLow Err 1 over Load Err 21 Under Load Err3 Low APW Err 4 Low ref Err 7 EEpr Error Err 14 Zero Error Err 21 CAL Error CAL data Error Batteries are weak The load on the platform ex ceeds the rated capacity of ihe scale overload condi tion Underload condition load cell signal is more than 9 divisions below zero APW is below minimum 01 lowed value Reference weight is below minimum value EEPROM hardware problem When ON ZERO OFF button is pressed the load on the pan exceeds zero menu setting Could be caused by a load on the pan At power up the load cell signal is outside the allow able limit Calibration incorrect Span point parameter check failed during program run ning Replace batteries Remove excess load Refer to the Trouble shooting Tables Press the ON ZERO Offbutton If problem persists refer to the troubleshooting sec tion 10 check load cell assembly Correct the APW setting Correct the reference weight setting Turn unit on and off and on again If error 7 remains replace the Main PC board gt Repair Procedures 3 5 Enter the Setup Menu and set the zero to a higher setting See Instruction Manual Perform a linearity calibration If this fails sub
30. 749 Load Cell Assembly 30kg TRSORS 1 6 71127150 Load Cell Assembly 3kg TC3RS 1 6 71128566 Load Cell Assembly 6kg TC6RS 1 6 71128567 Load Cell Assembly 15kg TC15RS 1 6 71141919 Load Cell Assembly 30kg 5 1 7 71134281 Main PCB Asembly TR 1 d 71138662 Main Asembly TC 1 8 See Note 1 Screw M4x6 2 9 See Note 1 Screw M3x8 2 10 See Note 1 Washer 3mm 2 1 See Note 1 Nut DSO26AS 12 See Note 1 Nut M3 GB6170 86 2 13 71133660 Harness PWR COM TR TC 1 14 71133035 Bottom Housing TR TC 1 15 71133036 Cover Battery TR TC 16 71127394 Contact Battery Positive TR TC 1 17 71127395 Contact Battery Dual TR TC 1 18 71133155 Sealing Cover TR 2 19 71127396 Contact Battery Negative TR TC 1 20 71123028 Foot w Nut TR TC 4 21 See Note 2 Screw Sealing M4x8 2 22 See Note 1 Screw M4x8 6 NOTES Item included in Fastener Kit P N 71139672 2 Item included in LFT Sealing Kit P N 71138587 5 3 CHAPTER 5 PARTS LISTS TABLE 5 1 TROOPER SCALE TR AND TROOPER COUNT SCALE TC PARTS LIST Cont ITEM NO PART NO DESCRIPTION QUANTITY 23 71192592 Display LCD TR 1 24 71138664 Display PC Board Assembly 1 25 71118243 Spacer Rubber TR TC 4 26 11116785 Display LCD TC 1 71139672 Fastener Kit TR TC 71138587 Sealing Kit TR TC 1 80500435 AC Adapter 120V 50 60Hz US 1 80500436 AC Adapter 230V 50 60Hz EU 1 80500437 AC Adapter 240V 50 60Hz UK 1 80500462 AC Adapter 240V 50
31. Locations Carefully remove the wires coming from J10 which is 5232 connector and which is used 10 connect the loadcell 4 Remove the four corner screws on the Main PC Board 5 Replace the Main PC Board and install the four screws previously removed NOTE Make sure that Jumper 1 and Jumper 2 are connected as shown in Figure 3 1 6 Replace the color coded wiring for connectors and J 10 Check color coded wiring is correctly installed See Figure 3 2 for wire color and locations 7 Replace the connectors to J6 and J7 on the Main PC Board 8 Put the jumper across both pins of W1 9 Position the upper housing in place over the scale and connect the flexible cable from the membrane switch to J5A connector on the Main PC board 3 2 CHAPTER 3 REPAIR PROCEDURES 3 2 REPLACING THE TROOPER SCALE MAIN PC BOARD Cont RS232 CONNECTOR TO LOAD CELL YELLOW GREEN P WHITE RED LFT LOCK SWITCH SHOWN IN THE UNLOCKED OFF POSITION 1 1 JUMP 2 EXC SIG SIG GND SEN JUMP 1 Figure 3 2 Trooper Scale RS Connector and Loadcell Connector Wiring 10 Check the LFT lock switch legal for trade switch S1 Make sure it is in the ON position 11 Turn on the scale When self testing is completed the display may indicate an error code This is normal 12 Do not turn off the power Switch LFT lock switch to its OFF position 13 Set the capac
32. PAIR PROCEDURES 10 Place the top cover and platform temporarily on the scale 11 Refer to Appendix A and perform a LIN calibration 12 Turn the scale off then on It will go through all the self testing 13 Reassemble the scale by replacing the six screws at the bottom of the scale which secure the upper housing 14 Replace the platform on top of the scale 15 After installation check all operations if possible set the original customer settings back into the scale and calibrate the scale DC POWER JACK BATTERY BOX RS232 CONNECTOR LOAD CELL ASSEMBLY FERRITE CORE BATTERY BOX amp CONNECTOR CABLES DISPLAY LOAD CELL CONNECTOR RS232 CABLE MEMBRANE SWITCH CONNECTORS MEMBRANE SWITCH CABLES SCALE BASE TOP COVER Figure 3 6 Trooper Count Scale Component Locations 3 10 CHAPTER 4 TESTING 4 TESTING Before and after servicing the Trooper Scale and Trooper Count Scale they should have an operational test and various performance tests made to ascertain whether or not the scale meets specifications Turn the scale 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 scale rests on is level and vibration free The masses used for the performance tests and adjustments must meet or exceed ASTM Class 4 or OIML F2 Tolerance 4 1 TROOPER SCALE OPERATIONAL TEST Connect the AC Ada
33. TER 1 INTRODUCTION 1 4 SERVICE STRATEGY The repair method for the Trooper Scale and Trooper Count Scale is the direct substitution of major assemblies The Trooper Scale contains 3 major replaceable assemblies Cover Assembly with Membrane Switch Load Cell Assembly with Frame and the Main PC Board with LCD The Trooper Count Scale contains 4 major replaceable assemblies Cover Assembly with Membrane Switch Display PC Board with LCD Load Cell Assembly with Frame and the Main PC Board This service manual contains sufficient information to isolate the problem replace the component test and restore the Scale to original factory specifications CHAPTER 1 INTRODUCTION CHAPTER 2 DIAGNOSIS 2 DIAGNOSIS This section contains information needed to properly evaluate the reported problem and diagnose its cause 2 1 SCALE SETUP AND EXAMINATION Set up the scale according to the Instruction manual Allow the scale to stabilize to room temperature Examine the scale for signs of corrosion or physical damage 2 2 PRELIMINARY CHECKS Power up the scale using the customer s ac adapter In the case where the scale will not power up check the ac adapter Observe and record the error codes and software revision Record all menu settings if possible as received 2 3 TROUBLESHOOTING TABLES Troubleshooting tables 2 1 through 2 14 identify actual types of problems that could be encountered with the scale Trooper Scales are covered in Tables 2 1 thr
34. Trooper Count Tools 2 7F Under Over Count The Library screen displays up to 60 part files each line representing a record that contains unique file information Each part file data are entered or changed manually selected record to be modified will be highlighted in yellow and are described as follows ID A fixed record location in the scale where the information is stored Part A user designated identifying number assigned to an item APW Average Piece Weight The total weight of a given number of pieces of the item divided by the number of pieces P Tare Pre set Tare The weight of the empty container When the P Tare field box is checked off Pre set Tare will be active during scale operation Under Over The under and over tolerance weight values With a value entered the checkweighing feature of the scale will be active during operation Count The accumulated piece count of the item When the Count field box is checked off Count Accumulation will be active during scale operation B 4 APPENDIX B TROOPER COUNT SCALE TOOLS e Unit The selected unit of measurement Select by scrolling through the available units kg Ib g or 02 Note Any changes 10 the record data will not be saved or take effect for scale operation until transferred into the scale or a file Refer to the followin
35. X0 20z 9600z X 0 507 Lineorily g 50 Repeatability 50 Off Center Load 50 4 5 TROOPER COUNT SCALE SPECIFICATIONS TABLE 4 2 TROOPER COUNT SCALE SPECIFICATIONS Model 1688 10688 oss 5 Default Capacity X Readability Ib 6016 X 0 01 Ib Default Capacity X Readability kg 30kg X 0 005kg Default Capacity X Readability 0 30000g X 5g Default Capacity X Readability 02 48002 0 102 96007 X 0 207 Type Approved Capacity X Readability 10 30lbXO Ollb 601 X 0 02Ib Type Approved Capacity X Readability kg 30kg X 0 01kg Type Approved Capacity X Readabilily g 30000g X 10g Type Approved Capacity X Readability oz 4800z X 0 202 96002 X 0 50z Lineorily 0 50 Repeatability 50 Of Center Load 50 4 6 CHAPTER 4 TESTING 4 6 COMMUNICATION TEST The Trooper Scale and Trooper Count Scale each contain a communication port for 95232 protocol communications The RS232 Interface is a bi directional interface that enables the scale to communicate with a printer or computer equipped with an RS232 serial port After the scale has been repaired and calibrated and all menu functions operate normally the communication function between the scale and a computer has to be checked For this test you will require a PC computer with communication capabilities such as a Hyper Terminal or a Terminal program that allows setting of communication parameters and an Ohaus RS 232 Cable P N 80500433 IBM PC 9 pin or a standard null mod
36. alled Incorrect battery installation Wiring harness defective or battery clips connection bro ken Membrane Switch defective Main PC Board is defective Check position of batteries Remove the 6 screws from the bottom cover of the scale carefully remove the platform top cover and remove the flex ible cable from the Main PC Board Check dc voltage at pins 1 and 3 of connector J6 on the Main PC Board See Figure 2 1 Voltage should read ap proximately 9 Volts dc If voltage is not present at the connector remove the 001 teries and make a continuity test be tween each of the connectors in the bat tery boxto connector J6 pins 1 and 3 on the Main PC Board Resistance should be ohms forthe red lead and ohms for the black lead If an open condition exists trace wiring and resolder or re place wiring as necessary If OK pro ceed See Table 2 3 H the scale fails to turn on with a new Membrane Switch the Main PC Board is defective and should be replaced gt Repair Procedures 3 2 2 2 CHAPTER 2 DIAGNOSIS TABLE 2 3 TROOPER SCALE DOES NOT RESPOND TO FRONT PANEL CONTROLS SYMPTOM PROBABLE CAUSE REMEDY Scale does not respond to front panel controls NOTE Use a known good ac adopter for this test Membrane Switch is defec tive 1 Co Open the scale remove six screws from the bottom of the scale Refer to Figure 2 2 Using an Ohm
37. cale Error 0087 eege Eege ege Ee 2 8 26 OOPS Count Scale a eae 2 15 2 7 Trooper Count Scale Error Code Table deer eebe tee 2 16 CHAPTER 3 REPAIR PROCEDURES 2 1 8 4 3 1 3 1 Replacing the Trooper Scale Membrane Switch 7 3 1 3 2 Replacing the Trooper Scale Main PC Board AAA 3 2 3 3 Replacing the Trooper Scale Load Cell 3 4 3 4 Replacing the Trooper Count Scale Membrane 3 6 3 5 Replacing the Trooper Count Scale Main PC Board 3 7 3 6 Replacing the Trooper Count Scale Display PC Board 3 8 3 7 Replacing the Trooper Count Scale Load Cell 0 2 727 3 9 CHAPTER 4 TESTING MURS 4 A A Trooper scale Operational EE 4 Segment MEE 4 4 2 Trooper Count Scale Operational esp iet 4 4 2 1 Segment Display test 4 1 429 110110 CS NS cet TUE 4 2 23 1 m 4 2 43 2 gu ie ele EE 4 4 EE 4 5 4 4 Trooper Scale SDECIICONORS EE 4 6 4 5 EE 4 6 46 02011111
38. ction 5 and verify operation If the above readings are within limits the Main PC Board is defective To check the Main PC Board if unsure about the load cell connect a known good load cell or load cell simulator to connector J4 as shown in Figure 2 1 Use an output of 0 mv V for CAL ZERO 1 mv V for span calibration If unable to calibrate the Main PC Board is defective Replace Main PC Board gt Repair Procedures 3 2 LOAD CELL OUTPUT READINGS MODEL SPAN SIGNAL TR3RS 4 0 5 0mv TROERS 3 5 4 5mv TR15RS 4 5 5 5mv TR3ORS 6 5 8 3mv NOTE Span signal readings are approximate If readings are slightly above or below these limits the loadcell may still function properly 2 5 CHAPTER 2 DIAGNOSIS TABLE 2 6 TROOPER SCALE COMMUNICATIONS FAILURE SYMPTOM PROBABLE CAUSE REMEDY Communications cannot be established with scale turned on Communication cable is not plugged in or the incorrect cable is being used Improper settings in the Print menu Main PC Board is defective Tighten connectors and use the proper cable Ensure thatthe communications param eters of the scale and periphal device match Replace Main PC Board gt Repair Procedures 3 2 Reassemblethe scale Perform tests in Section 5 and verify operation 2 6 CHAPTER 2 DIAGNOSIS 2 4 TROOPER SCALE DIAGRAMS Load Cell Membrane Switch TARE He onzo t
39. ction describes how to change individual components ofthe Trooper Scale and Trooper Count Scale When doing this please refer to the exploded view drawings and parts lists in section 5 Important After replacing components a functional check of the scale must always be carried out 3 1 REPLACING THE TROOPER SCALE MEMBRANE SWITCH The membrane switch is affixed to the upper housing of the scale To replace the membrane switch the scale must be disassembled to gain access to the switch connections 1 2 Remove power from the scale Carefully lift and remove the platform from the scale One rubber foot remains attached to the platform This ensures that the platform is properly located on the weighing load cell Turn the scale over and remove the six screws which hold the upper housing CAUTION Use care in the next step as the membrane switch wiring is attached to the PC board Place the scale in the upright position and carefully lift the upper housing from the bottom housing about two to three inches Reach under the upper housing from the front and carefully disconnect the flexible cable from connector J5A on the Main PC board On the upper housing lift up the defective membrane switch if necessary carefully prying it up with a knife and gently peel it off the upper housing CAUTION Do not use any solvents that may harm the finish or cause damage to the cover Carefully clean the upper housing membrane switch area
40. d Trooper Count Scale The exploded view drawings identifies the replaceable parts NOTE In all cases where a part is replaced the scale must be thoroughly checked after the replacement is made The scale MUST meet the parameters of all applicable specifications in this manual If further technical information is needed in the United States call toll free 1 800 526 0659 between 8 00 a m and 4 00 p m EST An Ohaus factory service technician will be available to provide assistance Outside the U S A please contact Ohaus Corporation 19A Chapin Road P O Box 2033 Pine Brook NJ 07058 USA Tel 973 377 9000 Fax 973 593 0359 5 CHAPTER 5 PARTS LISTS 5 1 Trooper Scale Trooper Count Scale Exploded View Figure 5 1 Exploded View of Trooper Scale and Trooper Count Scale 5 2 CHAPTER 5 PARTS LISTS TABLE 5 1 TROOPER SCALE TR AND TROOPER COUNT SCALE TC PARTS LIST ITEM NO PART NO DESCRIPTION QUANTITY 1 71133849 Platform Assembly TR TC 1 2 71133037 Membrane Switch TR 1 2 71138748 Membrane Switch TC 1 3 71102326 Level TR TC 1 4 71133160 Upper Housing Assy w Membrane Switch TR 1 4 71152365 Upper Housing Assy w Membrane Switch TC 1 5 See Note 1 Screw M4x8 4 6 71133746 Load Cell Assembly 3kg TR3RS 1 6 71133747 Load Cell Assembly 6kg TRGRS 1 6 71133748 Load Cell Assembly 15kg TRI5RS 1 6 71133
41. d at interval Where xxxx 1 to 3600 seconds Send as fast as possible continuous print Increment to next enabled unit Output software version For example TC30 Sr 1 20 To turn auto printing interval printing or continuous printing off send P to reset normal printing mode 4 8 CHAPTER 4 TESTING 4 6 3 Connecting the RS232 Interface Cont TABLE 4 4 COUNT SCALE 185232 COMMANDS LFT is OFF Same as pressing PRINT button Sends print data to peripheral device Output software version For example Sr 1 20 Same as pressing TARE If the Scale accepts the command it will respond If the Scale is in motion it will output CANT until the Scale is stable When stable tare is accepted NOTE If LFT is ON special tare rules apply Same as pressing ZERO button If the Scale accepts the command it will respond OK 4 6 4 PrintTest Remove all weight from the platform To zero the scale press the ON ZERO OFF button once Place a mass on the Platform Press PRINT Unit button the computer or a printer should record the weight value Refer to Tables 4 3 for the Trooper Scale and 4 4 for the Trooper Count Scale and try all commands and verify operation of the scale gt 4 9 CHAPTER 4 TESTING 4 10 CHAPTER 5 PARTS LISTS 5 PARTS LISTS This section of the manual contains exploded views and parts lists for the Trooper Scale an
42. e 5 Connect the color coded wiring from the load cell to connector 94 Check that color coded wiring is correctly installed See Figure 3 2 6 Put the jumper across both pins of W1 7 Position the upper housing in place over the scale and connect the flexible cable from the membrane switch to connector J5A on the Main PC board 8 Check the LFT lock switch Make sure it is in the ON position 9 onthe scale When self testing is completed the display may indicate an error code This is normal 10 Do not turn off the power Switch LFT lock switch to its OFF position 1 1 Calibrate the scale according to the instructions in Appendix A 12 After finishing all of the necessary configuration remove the jumper from W1 and keep the LFT lock switch in its OFF position 13 Turn the scale off then on It will go through all the self testing 14 If the scale locks up with software revision showing this means that W1 is in the closed position and the LFT lock switch is in the ON position Change them to the correct position W1 Open and LFT lock switch OFF 15 Reassemble the scale 16 Replace the platform on top of the scale 17 After installation check all operations if possible set the original customer settings back into the scale and calibrate the scale CHAPTER 3 REPAIR PROCEDURES 3 3 REPLACING THE TROOPER SCALE LOAD CELL ASSEMBLY Cont DC POWER JACK BATTERY BOX RS232 CONNECTOR LOAD CELL ASSEMBLY
43. ed and the displayed unit must be set to kg Set the scale readability to the factory default setting This can be done by means of the Setup Menu Reset function for the Trooper Count Scale and setting the Trooper Scale to kg scale passing each of these three tests complies with Ohaus specifications 4 3 1 Repeatability Test Repeatability is the standard deviation of a set of similar weight readings To determine the repeatability perform the following test 1 Zero the scale The reading on the display should be Okg 2 Select a test weight near the maximum capacity of the scale and place it on the center of the pan Observe and record the reading 3 Remove the test weight The reading should return to Og 4 Repeat this test for ten readings Calculate the standard deviation of the ten load readings using a calculator with statistical capabilities or use the following formula 222 Standard Deviation 6 A 2 1 n X weight reading in kg Mean average of 10 readings n number of readings A worksheet has been provided for entering the data and calculation results for the Standard Deviation Figure 4 3 Step by step instructions for calculating the standard deviation are provided in Figure 4 4 and a sample calculation is provided in Figure 4 5 4 2 CHAPTER 4 TESTING 4 3 1 Repeatability Test Cont Figure 4 3 Standard Deviation O Worksheet
44. em cable The RS232 Interface in the Trooper Scale and Trooper Count Scale can have its performance monitored using an external printer or computer connected fo the scale It is preferable to use a computer so commands can be sent to the scale to verify operation 4 6 1 Setting Trooper Scale Print Menu The Trooper Scale Print menu provides communication parameters which can be set to accommodate external printers or computers It contains the following submenus Reset Baud Rate Parity Bit Data Length Stop Bits Auto Print Interval Stable and save settings which enable you to program 5232 port parameters Set the Trooper Scale print menu to factory settings which should be Baud rate 2400 Parity Bit None Data Length 7 Stop Bits 2 Auto print Off Interval 1 and Stable Off Save these settings 4 6 2 Setting Trooper Count Scale Print Menu The Trooper Count Scale also contains a print menu with the following submenus Baud Rate Data Length Parity Bit Print Part No Print Count Print APW Print Net Print Tare Print Total PCS Print Gross print on Stable Print Header and Print Style Set the Trooper Count Scale Print menu to factory settings which should be Baud Rate 2400 Data Length 7 Parity Bit None Print Part No Off Print Count On Print APW On Print Net On Print Tare Off Print Total PCS On Print Gross Off Print on Stable Off Print Header Off and Print Style Col 4 7 CHAPTER 4 TESTING 4 6 3 Connecting the RS
45. g section The Library screen features 5 function buttons to read and save all or individual Library records Each button and its function is described as follows Read Scale Library Button Select this button to read extract the library data from the scale Library data will be uploaded from the scale and displayed on screen e Write Lib to Scale Button Selectthis button to write save all Library data displayed on screen into the scale Thereafter confirm the following acknowledgement screens to execute or cancel the process Write All Library Data to Scale x eee Write Library to Scale e Write Rec to Scale Button Selectthis button to write save data of a highlighted record into the scale Thereafter confirm the following acknowledgement screens to execute or cancel the process Write record data to scale wl LGS Jm 5 APPENDIX B TROOPER COUNT SCALE TOOLS Write A Record Data to Scale Read Library File Button Select this button to read extract all Library data from a file created from the Write to File Button in the Trooper Count Scale Tools program refer following section Specify the source directory folder and file name as prompted on the following Open screen Then select Open to execute the process Local Disk omputer Network P Write to File Button Select this button to write save all Library data displayed on
46. he Ll LI LI kg troubleshooting section Gross Brutto Remove calibration masses from platform NOTE If the Scale is to be used for legal for trade applications it must be calibrated and the Lock Switch must be set to lock out the menus Refer to the Instruction Manual sealing for legal for trade use A APPENDIX CALIBRATION A 2 TROOPER COUNT SCALE LINEARITY CALIBRATION The following example is with a 6kg Scale With the Scale ON press and hold the SAMPLE Menu button until CAL MENU is displayed Press the Enter button Press the M button Press the Enter button Press the M button then press the Enter but ton Follow display instructions WEIGHT DATA COUNT WEIGHT DATA COUNT inc LHL IE HL L LI _ LHL 5PHn WEIGHT COUNT ro E TT roy Lx _ LIIL roy E 5 9 ID oz IEN PAn B G APW MR COUNT kg g Net B G Ac MR M Scale is determining zero value WEIGHT DATA COUNT then WEIGHT 55 LAL hund kg PLRLE then kg g ID oz B G MR M PCS 9 B G
47. ity readability according to Table 4 1 in Chapter 4 of this manual Refer to Setup menu procedures in the Instruction manual 14 Calibrate the scale according to the Instructions in Appendix A 15 After finishing all of the necessary configuration remove the jumper from W1 and keep the LFT lock switch in its OFF position 16 Turn the scale off then on It will go through all the self testing 17 If the scale locks up with software revision showing this means that W1 is in the closed position and the LFT lock switch is in the ON position Change them to the correct position W1 Open and LFT lock switch OFF 18 Reassemble the scale 19 Replace the platform on top of the scale 20 After installation check all operations if possible set the original customer settings back into the scale and calibrate the scale 3 3 CHAPTER 3 REPAIR PROCEDURES 3 3 REPLACING THE TROOPER SCALE LOAD CELL ASSEMBLY The Load Cell Assembly is centrally located inside the scale See Figure 3 3 The load cell is factory assembled and the down stops are preadjusted There are no adjustments to be made on this assembly after installation 1 Perform steps 1 through 4 of paragraph 3 1 2 Carefully remove the load cell wires from connector See Figure 3 2 for wire color and locations 3 Remove the four screws holding the Load Cell Assembly to the bottom housing 4 Lift the Load Cell Assembly out of the bottom housing and replace with a new on
48. nications testing procedures Chapter 5 Parts Lists Contains exploded views of Trooper Scale and Trooper Count Scale identifying all serviceable replacement components with associated parts lists Appendix A Calibration Contains linearity calibration procedures for the Trooper Scale and Trooper Count Scale Appendix B Trooper Count Scale Tools Contains information on scale configuration library data and testing output commands from a computer 1 1 SERVICE FACILITIES The service area should be a stable environment The bench area should be clean and should contain an antistatic mat with a personnel grounding clip to protect internal circuit boards The ideal electrical power source for the scales should be a dedicated line to avoid sudden fluctuations or voltage drops caused by external equipment drawing heavy current The service area for the scales should be away from direct sunlight overhead heating or air conditioning ducts magnetic fields such as motors or large transformers or near vibrating sources such as machinery motors or vibrating equipment The power outlet should be grounded for safety Sufficient space should be provided around the scale as not to be affected by other equipment This will ensure that the scale is operated under ideal conditions CHAPTER 1 INTRODUCTION 1 2 TOOLS AND EQUIPMENT 1 2 1 Standard Tools and Test Equipment The service shop should contain the following equipment 1 Digital Voltmeter DVM
49. or settings to establish functional communications e Library error Read Library File The following error message appears after selecting the Read Library File Button from the Library Screen when attempting to read a file that was not created from the Write to File Button in the Trooper Count Tools program Open a file created from the Write to File Button Error Library error Part number entry The following error message appears after entering non numeric entries in the Part field in the Library Screen Only numeric entries are allowed in this field APPENDIX B TROOPER COUNT SCALE TOOLS B 10 OHAUS Ohaus Corporation 19A Chapin Road P O Box 2033 Pine Brook NJ 07058 USA Tel 973 377 9000 Fax 973 593 0359 www ohaus com With offices worldwide www ohaus com 8 0 2 5 09 5 2 P N 80250952 Printed in USA Ohaus Corporation 2004 all rights reserved
50. ough 2 7 Trooper Count Scales are covered in Tables 2 8 through 2 14 The troubleshooting tables refer to interconnection and wiring diagrams in this section to assist in locating the problem TABLE 2 1 TROOPER SCALE WILL NOT TURN ON WITH AC ADAPTER SYMPTOM PROBABLE CAUSE REMEDY Scale will not turn on with AC Adapter defective Check the ac adapter voltage output adapter supplied The ac adapter output should measure 12 16 Volts dc If voltage is low or nonexistent replace the ac adapter If OK proceed DC input connector at rear of Disconnect the ac adapter Remove scale is defective the 6 screws from the bottom cover of ihe scale carefully remove the form top cover and disconnect the flexible cable from the Main PC Board See Figure 2 1 Reconnect the ac adapter to the scale Check dc voltage at pins 1 and 4 of connector J7 on the Main PC Board Should read between 12 16 Volts dc power off 12 14 Volts dc power on If voltage is present replace the Main PC Board If OK proceed Membrane Switch defective See Table 2 3 Main PC Board is defective If the scale fails to turn on with a new Membrane Switch the Main PC Board is defective and should be replaced gt Repair Procedures 3 2 2 1 CHAPTER 2 DIAGNOSIS TABLE 2 2 TROOPER SCALE WILL NOT TURN ON USING BATTERIES SYMPTOM PROBABLE CAUSE REMEDY Scale will not tum on with new batteries inst
51. ow fails substitute the load cell assembly able limit and perform the linearity calibration again Referto Table 2 5 If the substi tute load cell does not correct the condi tion re install the original load cell and replace the Main PC board gt Repair Procedures3 2 Error 21 Checksum error Replace the load cell gt Repair Proce dures 3 3 and or Main PC board as required gt Repair Procedures3 2 Recalibrate and check 2 8 CHAPTER 2 DIAGNOSIS TABLE 2 8 TROOPER COUNT SCALE WILL NOT TURN ON WITH AC ADAPTER SYMPTOM PROBABLE CAUSE REMEDY Scale will not turn on with AC adapter supplied Adapter defective DC input connector at rear of scale is defective Membrane switch defective Main PC Board is defective Check the ac adapter voltage output The ac adapter output should measure 12 16 Volts dc If voltage is low or nonexistent replace the ac adapter H OK proceed Disconnect the ac adapter Remove the 6 screws from the bottom cover of the scale carefully remove the platform top cover and remove three flexible cables from the Main PC board Reconnect the ac adapter to the scale Check dc voltage at pins 1 and 4 of connector J8 on the Main PC board Should read between 12 16 Volts dc If voltage is not present replace the Main PC board See Figure 2 3 If OK pro ceed See Table 2 10 If the scale fails to turn on with a new membrane switch the Main PC
52. oximate If readings are slightly above or below these limits the loadcell may still function properly TABLE 2 13 TROOPER COUNT SCALE COMMUNICATIONS FAILURE SYMPTOM PROBABLE CAUSE REMEDY Communications cannot be established with scale turned on Communication cable is not plugged in or the incorrect cable is being used Improper settings in the Print menu Main PC Board is defective Tighten connectors and use the proper cable Ensure that the communications param eters of the scale and periphal device match Replace Main PC Board gt Repair Pro cedures 3 5 Reassemble the scale Perform tests in Chapter 4 and verify operation CHAPTER 2 DIAGNOSIS 2 6 TROOPER COUNT SCALE DIAGRAM Juno 1900041 e z 6 Iu 2 QNO 9 qa v ASt 1831 2 QNO Quvoa AV Veig H3dOOH L Ir of Sf or er Hi DU Ir HOLIMS SNVUSNSN M ATddNS H3MOd CN 9XAS HH S 39NVHO N59 Y N33H5 SLIHM 918 OH 916 el N wm D TO 0 01 2 15 CHAPTER 2 DIAGNOSIS 2
53. pter into a suitable power source and connect to the scale 4 1 1 Segment Display Test Turn the scale on all segments are enabled and displayed breifly followed by a software revision number This is a segment display test Figure 4 1 is a full display test pogone ekg BAT Figure 4 1 Trooper Scale Segment Displays 4 2 TROOPER COUNT SCALE OPERATIONAL TEST Connect the AC Adapter into a suitable power source and connect to the scale 4 2 1 Segment Display Test Turn the scale on all segments are enabled and displayed breifly followed by a software revision number This is a segment display test Figure 4 2 is a full display test WEIGHT DATA COUNT Lui g oz Net B G MR M p PCS Figure 4 2 Trooper Count Scale Segment Displays NOTE For menu structures operation calibration procedures and menu lockout procedures refer to the respective Instruction manuals 4 1 CHAPTER 4 TESTING 4 3 PERFORMANCE TESTS Accurate performance of the Trooper Scale and Trooper Count Scale is determined by a series of three performance tests These tests are used to evaluate the scale performance before and after repairs Each scale tested must meet the requirements specified in each test as well as the specifications listed in Tables 4 1 and 4 2 Before proceeding with the following tests all the procedures beginning with section 4 must be successfully complet
54. r housing CAUTION Do not use any solvents that may harm the finish or cause damage to the cover Carefully clean the upper housing membrane switch area removing all traces of adhesive The best method is to use a flat razor blade Insert the two cables from the membrane switch through the hole in the upper housing Peel off the protective film from the new membrane switch and carefully affix to the upper housing Press the membrane switch down uniformly Using your fingers with a cloth roll from the center of the membrane switch outward towards the edges to remove any air bubbles that may be trapped Position the upper housing in place over the scale and connect the two flexible cables from the membrane switch to connectors J2 and J3 on the Main PC board and the single cable from the display PC board to connector J4 on the Main PC board 10 Reassemble the scale 11 Replace the platform on top of the scale 3 6 CHAPTER 3 REPAIR PROCEDURES 3 5 REPLACING THE TROOPER COUNT SCALE MAIN PC BOARD NOTE Do not attempt this procedure unless you have the Trooper Count Scale Tools program The Main PC Board is located inside the scale towards the front To replace the Main PC Board it is necessary to disassemble the scale After replacement use the OHAUS TROOPER COUNT SCALE TOOLS program to enter data into the EEPROM CAUTION THE TROOPER COUNT SCALE PC BOARD WILL NOT OPERATE UNLESS THE TROOPER COUNT SCALE TOOLS PROGRAM IS USED 1
55. rned on the display will show Error 21 gt Cal gt Data 11 Refer to Appendix B and start Trooper Count Scale Tools 12 Select the model of the Trooper Count Scale in the Model box 13 Enter the serial number in the serial number box 14 Check the box labeled Do Calibration After Config 15 Click on the button labeled Write Config Data to Scale 16 The configuration data will be written to the scale and a calibration will start Follow the on screen directions 17 Turn the scale off then on It will go through all the self testing 18 Reassemble the scale 19 Replace the platform on top of the scale 20 After installation check all operations if possible set the original customer settings back into the scale and calibrate the scale 3 8 CHAPTER 3 REPAIR PROCEDURES 3 6 REPLACING THE TROOPER COUNT SCALE DISPLAY PC BOARD The Display PC Board is located on the inside of the upper housing To replace the Display PC Board it is necessary to disassemble the scale 1 2 Perform steps 1 through 4 of paragraph 3 4 Remove the connector plugs from connectors J2 J3 and J4 from the Main PC Board which is the membrane switch and display cables See Figure 3 4 Remove the four corner screws on the Display PC Board Replace the Display PC Board and install the four screws previously removed Position the upper housing in place over the scale and connect the two flexible cables from the membrane switch to connectors J2 and
56. stitute the load cell assembly and perform the linearity calibration again Refer to Table 2 12 Ifthe substitute load cell does not correct the condition re install the original load cell and replace the Main PC board Repair Procedures 3 5 Recalibrate scale Ifthe problem persists replace the Main PC board or Load Cell Recalibrate scale Ifthe problem persists replace the Main PC board or Load Cell 2 16 CHAPTER 2 DIAGNOSIS TABLE 2 14 TROOPER COUNT SCALE ERROR CODES Cont SYMPTOM CAUSE REMEDY CAP data Error Load Error Entry Too High Start Stable Error Capacity point parameter check failed during program running Incorrect calibration weight was used keypad input number is over limit Scale is not stable at power Interference between plat form and load cell Recalibrate scale If the problem per sists replace the Main PC board or Load Cell Recalibrate the scale Enter proper value within limits Check that the surface the scale is rest ing on is stable Check that proper clearances exist be tween the cover and the load cell under the platform 2 17 CHAPTER 2 DIAGNOSIS Figure 2 4 Trooper Count Scale Membrane Switch Wiring Diagram 2 18 CHAPTER 3 REPAIR PROCEDURES 3 REPAIR PROCEDURES This se
57. y PC board is replaced as a whole assembly Check procedures in Table 2 8 first and verify that other prob lems do not exist Install a new display PC board connect all cables gt Repair Procedures 3 6 Put the cover and platform in place Do not install cover screws Turn on the scale and observe the dis play If the display functions properly install the cover screws If the display fails to operate continue Replace the Main PC board reassemble perform tests in Section 5 and verify Operation gt Repair Procedures 3 5 CHAPTER 2 DIAGNOSIS TABLE 2 12 TROOPER COUNT SCALE CANNOT CALIBRATE SYMPTOM PROBABLE CAUSE REMEDY Scale can be turned on but will not calibrate Incorrect weights The software lock menu is set ON LOC CAL ON Load cell assembly defec tive Verify that proper weights are used Set the software lock menu to OFF Ac cess to the software switch is when the hardware switch is OFF Remove the 6 screws from the bottom cover ofthe scale Carefully remove the platform Lift the top cover and lay aside leaving the cables connected to the Main PC Board With the scale plugged in and turned on measure voltage on terminals EXE and EXE The nominal voltage should be 5 V dc If the voltage is much lower disconnect the load cell from the Main PC Board and measure again If 5V dc is present the load cell may be shorted and requires replacement With
Download Pdf Manuals
Related Search