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Mettler-Toledo AG Laboratory & Weighing Technologies Market Support & Service Management 8606 Greifensee Switzerland +41 44 944

36 36 helpdesk.lms@mt.com http://www.mt.com

HG63

Service manual METTLER TOLEDO HG and HR Moisture Analyzers


First Edition 08/2007

HG53
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Overview of chapters Index

Chapte r Chapte r

HG-F

Mettler-Toledo AG 2007, File No. 11780933 8.12 Edition 08/2007, CD No. 11780410, produced in Switzerland

070731

Chapter Overview
1 - Introduction Using the Service Manual Designation Concept General information Hazard warnings 7 - LARS Testing and adjusting the balances with LARS

2 - Safety

8 - Adjusting in the Service Menu

Adjustment possibilities without LARS

3 - Spare Parts

Exploded-view drawings and spare-parts lists, packaging

9 - Adjustment Data

Tables of adjustment tolerances and technical data of the balances

4 - Checks

Instructions for preventive maintenance

10 - Accessories

Often used accessories

5 - Troubleshooting

Problems, causes, and remedies

11 - Service Aids

Software, interfaces, gages, tools

6 - Repair

Instructions for repair

12 - SOPs

Preventive Maintenance Instructions and Report

HG and HR Moisture Analyzers

Chapter Overview

1 - Introduction

Introduction
List of Contents
1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.2 1.2.1 1.2.2 1.3 1.4 1.5 Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Purpose of the Service Manual . . . . . . . . . . . . . . . . . 1-2 Previous Knowledge Required . . . . . . . . . . . . . . . . . 1-2 Service Manual Structure . . . . . . . . . . . . . . . . . . . . . 1-2 Navigating on the Screen . . . . . . . . . . . . . . . . . . . . . 1-3 Designation Concept. . . . . . . . . . . . . . . . . . . . . . . . 1-4 Type Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Serial Number Decoding . . . . . . . . . . . . . . . . . . . . . . 1-5 Type Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Document Status . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

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HG and HR Moisture Analyzers

Chapter Overview

1 - Introduction Service Manual

1.1
1.1.1

Service Manual
Purpose of the Service Manual

1.1.3

Service Manual Structure

The sequence of the 12 chapters largely corresponds to the sequence of the operations for repairing a balance: checking troubleshooting repair adjustment

The Service Manual (SMA) provides support to service personnel of METTLER TOLEDO, or other persons authorized by METTLER TOLEDO, when performing maintenance and repairs on the unit(s) described in this Service Manual.

1.1.2

Previous Knowledge Required

The Service Manual is designed for display on a computer screen.

Persons using the Service Manual must fulfill the following basic knowledge requirements regarding the handling of METTLER TOLEDO products and associated software: Understanding of the Operating Instructions of the respective equipment (see LabTec service expert DVD or http://www.extranet.mt.com LabTec Market Support). Experience with LARS (LabTec Repair and Service Software). Ability to load new software into the balance from the Internet using LARS (see LabTec service expert DVD or http://www.extranet.mt.com LabTec Market Support). Basic knowledge of using Adobe Acrobat Reader METTLER TOLEDO offers service courses which include this basic knowledge.

Tables of Contents / Index


Tools for rapid location of the required information: Chapter Overview Index Table of contents for each chapter

Header
left Instrument Name center Link to Chapter Overview right Chapter Name Subsection

Footer
SMA Number, Issue Date Chapter Number-Page Number

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HG and HR Moisture Analyzers

Chapter Overview

1 - Introduction Service Manual

1.1.4

Navigating on the Screen

For navigation in the Service Manual, use the functions of Adobe Acrobat Reader or the (blue) hyperlinks in the document.

Navigation with Adobe Acrobat Reader


E D E F G Navigation using the Adobe Acrobat Reader toolbar: A C D C E F B G A Open/close the navigation window B Zoom Page forward/backward Go to start/end of document Go to Previous View (e.g. return to the page with the "link origin") Go to Next View (e.g. from the page with the "link origin" back to the "linked page")

Full-screen mode
Note: Full-screen mode is functioning only when the document has been downloaded. It does not work when opening the document on the Service-DVD! Key combinations for navigation in full-screen mode: Ctrl+L Esc In full-screen mode, the document is displayed without the toolbar. Ctrl++ Ctrl-Switch to full-screen Reset to normal view Zoom in Zoom out Page forward/backward Return to previous view/page
1-3

Alt+
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HG and HR Moisture Analyzers

Chapter Overview

1 - Introduction Designation Concept

1.2
1.2.1

Designation Concept
Type Plate
A Type designation A B C B Serial number (SNR) C Type definition number (TDNR) of moisture analyzer when leaving the factory.

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Chapter Overview

1 - Introduction Designation Concept

1.2.2

Serial Number Decoding


11 25 01 0001
0001 = consecutive number within a production week 01 = production week (01 - 52) 25 = production year 2004. Offset = 21 (26 = 2005) etc. 11 = production site Switzerland / 12 = production site China

as of 2004 - example with SNR 1125010001

up to 31.12.2003 production site Switzerland, example with SNR 1118420763

11 18 42 0763
0763 = consecutive number within a production week 42 = production week (01 - 52) 18 = production year 1999. Offset = 19 (24 = 2005) 11 = MTLabTec (Switzerland) up to 31.12.2003 production site China, example with SNR 1202440020

12 02 44 0020
0020 = consecutive number within a production week 44 = production week (01 - 52) 02 = production year (05 = 2005) 12 = MTCS (China) Link to Serial Number Decoder on Extranet: http://www.extranet.mt.com/lab/technic/technic.asp

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HG and HR Moisture Analyzers

Chapter Overview

1 - Introduction Type Overview

1.3

Type Overview
Weighing cell

Type Designation

HG53
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HG63

HR73
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A..

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00214670

HR83

Spare parts

Top housing, CPU- and power supply board, sample chamber drive Sample chamber and ventilation Sample chamber with weighing cell Dryer unit
Mettler-Toledo AG

see Section 3.1 see Section 3.2 see Section 3.3 see Section 3.4
1-6

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Chapter Overview

1 - Introduction Type Overview

Type Designation

Weighing cell

HG-F

HG-F-P

00214670

Spare parts

Top housing, CPU- and power supply board, sample chamber drive Sample chamber and ventilation Sample chamber with weighing cell Dryer unit

see Section 3.1 see Section 3.2 see Section 3.3 see Section 3.4

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HG and HR Moisture Analyzers

Chapter Overview

1 - Introduction Abbreviations

1.4
/A c/w CW CCW HB HG HR LARS MJ /M SMA SNR SOP SW TDNR w/o

Abbreviations
Certified balance country specific (except European countries) complete with Clockwise Counter Clockwise Halogen Basic Halogen Standard Halogen Professional LabTec Repair and Service Software Moisture Junior Certified balance Europe Service Manual Serial Number Standard Operating Procedure Software Type Definition Number without

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HG and HR Moisture Analyzers

Chapter Overview

1 - Introduction Document Status

1.5

Document Status
Date of change 08/2007 Modified pages Short description of Change First edition

Document number 11780933 8.12

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HG and HR Moisture Analyzers

Chapter Overview

2 - Safety

Safety
List of Contents
2.1 2.2 2.3 2.4 2.5 Before starting service work . . . . . . . . . . . . . . . . . 2-2 Pictograms used in this manual . . . . . . . . . . . . . . 2-2 Text markers used. . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Disposal of service material and replaced parts . 2-2 State of the art . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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HG and HR Moisture Analyzers

Chapter Overview

2 - Safety Before starting service work

2.1

Before starting service work

2.3

Text markers used


Important information regarding handling

Read the Operating Instructions to familiarize yourself with the functions of the system. Observe all safety instructions in this Service Manual. Observe any safety instructions received from the customer. Be specially sure to observe safety instructions which are closely related to your service work.

Warning Attention Note

2.4

Disposal of service material and replaced parts

2.2

Pictograms used in this manual


General warning

Service materials (cleaning cloths, cleaning agents, etc.) and replaced parts must be disposed of: in accordance with the specific customer's regulations in accordance with the specific regulations of the respective country.

Warning of an electric voltage

2.5

State of the art

Warning of a hot surface

This Service Manual corresponds to the state of the art at the date of issue (e.g. 08/2007).

Warning of flammable material

Electrostatic sensitive devices

General attention

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HG and HR Moisture Analyzers

Chapter Overview

3 - Spare Parts

Spare Parts
List of Contents
3.1 3.2 3.3 3.4 3.5 3.6 Housing, CPU- and Power Supply Board, Sample Chamber Drive . . . . . . . . . . . . . . . . . . . . . . 3-2 Drawer Compartment, Ventilation . . . . . . . . . . . . . 3-3 Sample Chamber with Weighing Cell . . . . . . . . . . 3-4 Dryer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Weighing Cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Packaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

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HG and HR Moisture Analyzers

Chapter Overview 3 - Spare Parts Housing, CPU- and Power Supply Board, Sample Chamber Drive

3.1
46 53 54 55 45

Housing, CPU- and Power Supply Board, Sample Chamber Drive


Item Designation HR73
48 49 47 44

HR83 00214405 00214760 00086330 00214426 00214675 00214411 00089928 00225031 00225027 00089290 00214697 00214644 00214762 00214721 00210374 00214722 00214324 00214444 00214726 00214337 00214681 00214673 00214372

Part No. HG53 00214405 00214671 00086330 00214426 00214675 00214411 00089928 00225031 00225027 00089290 00214697 00214644 00214677 00214352 00210374 00214353 00214324 00214444 00214320 00214726 00214337 00214681 00214673 00214372

HG63 00214405 00214760 00086330 00214426 00214675 00214411 00089928 00225031 00225027 00089290 00214697 00214644 00214761 00214720 00210374 00214722 00214324 00214444 00214726 00214337 00214681 00214673 00214372

HG-F 00214405 00214755 00086330 00214426 00214675 00214411 00089928 00225031 00225027 00089290 00214697 00214644 00214756 00214750 00210374 00214722 00214324 00214444 00214726 00214337 00214681 00214673 00214372

12

9 10 11 12 13 14 15 16 17 18 36 40 44 45 46 47 48 49 50 51 53 54 55

CPU board Program EPROM Rechargeable battery Backlighting Sample chamber drive Power supply board Power receptacle CAN port CAN cover Microfuse cap Sample chamber cable with connection board EMC spring, front Top housing (with keypad) Membrane keypad with cable Level cover Model strip Cover without paper slot 1) Cover with paper slot Bottom housing Leveling screw Printing unit Printer board with holder Holder for printer

00214405 00214671 00086330 00214426 00214675 00214411 00089928 00225031 00225027 00089290 00214697 00214644 00214676 00214364 00210374 00214365 00214324 00214444 00214320 00214726 00214337 00214681 00214673 00214372

9 10 11

40

13 15 18 17 16

1) For types without printer, i.e.HR73, HR83, HG53, HG63, HG-F (HR73-P, HR83-P, HG53-P, HG63-P, HG-F-P: with printer)

36

51 14 50

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HG and HR Moisture Analyzers

Chapter Overview

3 - Spare Parts Drawer Compartment, Ventilation

3.2

Drawer Compartment, Ventilation


Item Designation HR73 19 20 21 22 23 24 25 26 27 28 37 41 52 Level Pivot bearing, left Pivot bearing, right Closure lever Contact block housing Contact block Radiator cable Temperature sensor Fan Air duct, rear Transport safety EMC spring, rear Guide rail 00238311 00214329 00214330 00214395 00214331 00299037 00214427 00214349 00214622 00214613 00214757 00214643 00214328 HR83 00238311 00214329 00214330 00214395 00214331 00299037 00214427 00214349 00214622 00214613 00214757 00214643 00214328 Part No. HG53 00238311 00214329 00214330 00214395 00214331 00299037 00214427 00214349 00214622 00214613 00214757 00214643 00214328 HG63 00238311 00214329 00214330 00214395 00214331 00299037 00214427 00214349 00214622 00214613 00214757 00214643 00214328 HG-F 00238311 00214329 00214330 00214395 00214331 00299037 00214427 00214349 00214622 00214613 00214757 00214643 00214328

19 26 24 23 22 41 25 20 21 22 27

28

13

52 37

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3-3

HG and HR Moisture Analyzers

Chapter Overview

3 - Spare Parts Sample Chamber with Weighing Cell

3.3

Sample Chamber with Weighing Cell


57
Item Designation HR73 29 30 31 32 33 34 Draft shield Sample pan holder Heat shield Sample chamber front Guide roller, lower, 1 piece Supporting roller, lower, 1 piece Weighing cell Bearing sleeve Tension spring Gear rack EMC compression spring Sample pan handler Weighing cell cable Cell cable Repair kit Supporting roller, upper, 2 pcs Guide roller, upper, 2 pcs Drawer bottom 00214368 00214642 00214624 00214393 00214733 00214327 1) 00214480 1) 00214670 00214386 00214496 00214332 11600064 00214526 00214634 00224409 00214747 1) 1) 00214371 HR83 00214368 00214642 00214624 00214733 00214327 00214480 00214670 00214386 00214496 00214332 11600064 00214526 00214634 00224409 ---------00214764 00214763 00214371 Part No. HG53 00214368 00214642 00214624 00214393 00214733 00214327 1) 00214480 1) 00214670 00214386 00214496 00214332 11600064 00214526 00214634 00224409 00214747 1) 1) 00214371 HG63 00214368 00214642 00214624 00214733 00214327 00214480 00214670 00214386 00214496 00214332 11600064 00214526 00214634 00224409 ---------00214764 00214763 00214371 HG-F 00214368 00214642 00214624 00214733 00214327 00214480 00214670 00214386 00214496 00214332 11600064 00214526 00214634 00224409 00214747 00214764 00214763 00214371

30

29

31 58 36
35 38 39 42 43 57 58 59 60 61 62 63

32

59

39

35 39

1) Use repair kit item 60

61 38 34

42

43 63 33 62

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3-4

HG and HR Moisture Analyzers

Chapter Overview

3 - Spare Parts Dryer Unit

3.4

Dryer Unit
Item Designation HR73 1 2 3
1

HR83 00214734 00214417 00214418 00214737 00214738 00214360 00214382 00214698 00214355 00214356 00214326

Part No. HG53 00214344 00214734 00214417 00214418 00214737 00214738 00214360 00214382 00214698 00214355 00214356 00214326

HG63 00214734 00214417 00214418 00214737 00214738 00214360 00214382 00214698 00214355 00214356 00214326

HG-F 00214734 00214417 00214418 00214737 00214738 00214360 00214382 00214698 00214355 00214356 00214326

Dryer unit housing Halogen radiator 110V Halogen radiator 230V Dryer unit 110V Dryer unit 230V Protective glass Reflector Over-temperature switch Metal contact, left Metal contact, right Heater housing

00214344 00214734 00214417 00214418 00214737 00214738 00214360 00214382 00214698 00214355 00214356 00214326

4 5 6 7 8 56

56

8 6 7

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3-5

HG and HR Moisture Analyzers

Chapter Overview

3 - Spare Parts Weighing Cell

3.5

Weighing Cell
Item 1
1
7

Designation Weighing cell complete Detector Ref. resistor 0.5 W 0.5% 680 Lever Contact strips Hook Guide, upper 1 Upper guide 4 Cup washer 4 Screw M4 x 10 mm

Note

Part No. 00214670 00224402 00081873 00600166

2 3 4 5 6 7

10 pcs

00043540 00224157 00600161

9 4 2

Guide, lower 1 Lower guide 4 Conical spring washer 4 Screw M4 x 10 mm

00600160

5 10

Flexible bearing 12 Screw M4 x 16 mm 12 Cup washer

6 pcs

00600158

10
3

Link Cup washer 6 Screw M4 x 16 mm 6 Screw M4 x 20 mm

6 pcs

00600164

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3-6

HG and HR Moisture Analyzers

Chapter Overview

3 - Spare Parts Packaging

3.6

Packaging
Item 1 3 Designation Export Carton Complete Export Carton with foam packaging Part No. 00214605 00214765

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3-7

HG and HR Moisture Analyzers

Chapter Overview

4 - Checks

Checks
List of Contents
4.1 4.2 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Performing the Checks . . . . . . . . . . . . . . . . . . . . . . 4-2

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4-1

HG and HR Moisture Analyzers

Chapter Overview

4 - Checks Instructions

4.1

Instructions

Please find the instructions as what to look for and how to proceed in the document Preventive Maintenance - Instructions (Chapter 12)

4.2

Performing the Checks

Note that for certain tasks, e.g. Function Check, the system needs to be acclimatized for approx. 30 minutes.

Print out the document Preventive Maintenance - Report in Chapter 12 and fill in the form as you proceed with preventive maintenance.

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HG and HR Moisture Analyzers

Chapter Overview

5 - Troubleshooting

Troubleshooting
List of Contents
5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7 5.1.8 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 Hardware Related Problems. . . . . . . . . . . . . . . . . . 5-2 Moisture Analyzer cannot be switched on . . . . . . . . . 5-2 Some Keys do not respond . . . . . . . . . . . . . . . . . . . . 5-2 Keypad does not function . . . . . . . . . . . . . . . . . . . . . 5-2 Halogen Lamp does not switch on after Start . . . . . 5-3 Add on Printer does not print some Characters . . . . 5-3 Sample Chamber does not move in and out . . . . . . . 5-4 Sample Chamber does not open/close completely . . 5-4 Wrong instrument designation on print-outs or in LARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Indications from Display. . . . . . . . . . . . . . . . . . . . . 5-5 Some Pixels of the Display do not light up . . . . . . . . 5-5 Temperature Indication rises above 205 C . . . . . . . 5-5 Unstable Weight Indication . . . . . . . . . . . . . . . . . . . . 5-5 Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 System Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

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5-1

HG and HR Moisture Analyzers

Chapter Overview

5 - Troubleshooting Hardware Related Problems

5.1
5.1.1

Hardware Related Problems


Moisture Analyzer cannot be switched on
Possible cause 1 Power supply cable not connected or no power supply voltage 2 Blown fuse Diagnostic Check Remedy Connect mains cable or reestablish mains supply voltage. The power supply is designed for 100...240 VAC, the drying unit however for 110 or 230 VAC. Check whether the correct drying unit is installed. Then replace the fuse. Connect or replace cable. Replace power supply board, see Section 6.3.16.

Error symptom Moisture analyzer cannot be switched on

Check

3 Cable inside instrument disconnected or faulty 4 Faulty power supply board

Check Check

5.1.2

Some Keys do not respond


Possible cause 1 "Key protection" or "Procedures off selected 2 Conductive path of keypad cable interrupted due to kink in cable Diagnostic Check Check Remedy Select "Key protection off" and in item 14 "Procedures on (see Operating Instructions) Replace membrane keypad, see Section 6.3.5.

Error symptom Some keys do not respond

5.1.3

Keypad does not function


Possible cause 1 Keypad cable disconnected 2 Keypad faulty Diagnostic Check Check Remedy Connect keypad cable, see Section 6.2.2. Replace Membrane Keypad, see Section 6.3.5.

Error symptom Keypad does not function

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HG and HR Moisture Analyzers

Chapter Overview

5 - Troubleshooting Hardware Related Problems

5.1.4

Halogen Lamp does not switch on after Start


Possible cause 1 Over-temperature switch has responded 2 Faulty over-temperature switch 3 Lamp contacts of drying unit bent or faulty 4 Faulty halogen lamp 5 Temperature sensor disconnected 6 Faulty temperature sensor 7 Faulty sample chamber cable 8 Faulty power supply board 9 Faulty CPU board Diagnostic Check Remedy Press switch with finger to reset, or on older versions wait 10 minutes until it resets automatically, see Section 6.3.3. Replace over-temperature switch if resistance after resetting is > 1 Ohm, see Section 6.3.3. Replace contact block, see Section 6.3.8, or contact plate, see Section 6.3.8. Replace halogen lamp if resistance is > 20 Ohm, (check whether 110 or 230 VAC). See Section 6.3.2. Connect temperature sensor, see Section 6.3.7. Replace temperature sensor, see Section 6.3.7. Replace sample chamber cable, see Section 6.3.22. Replace power supply board, see Section 6.3.16. Replace CPU board, see Section 6.3.12.

Error symptom Halogen lamp does not switch on after Start

Check resistance Check Check resistance of lamp and lamp voltage Check Check Check Check Check

5.1.5

Add on Printer does not print some Characters


Possible cause 1 Printer board not plugged in straight so some pins are bent at an angle and without contact Diagnostic Check Remedy Remove printer and straighten pins.

Error symptom Add on printer does not print some characters

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5-3

HG and HR Moisture Analyzers

Chapter Overview

5 - Troubleshooting Hardware Related Problems

5.1.6

Sample Chamber does not move in and out


Possible cause 1 Plug of sample chamber drive disconnected 2 Toothed belt of sample chamber drive faulty Diagnostic Check Check Remedy Connect, see Section 6.3.22. Replace sample chamber drive, see Section 6.3.18.

Error symptom Sample chamber does not move in and out

5.1.7

Sample Chamber does not open/close completely


Possible cause 1 Old type rollers installed 2 Soiled rails or rollers Diagnostic Rollers without bearings Remedy Replace all rollers with Repair Kit item 60 (page 3-4). See Section 6.3.21. Clean rails or rollers

Error symptom Sample chamber does not open/close completely, changes direction on the way

5.1.8

Wrong instrument designation on print-outs or in LARS


Possible cause 1 CPU PCB was previously installed in another instrument (e.g. for 'trial and error') Diagnostic Memorizing effect of (previous) instrument name Remedy Reset PCB (short-circuit keyboard connector pins), see Section 6.3.12.

Error symptom Wrong instrument designation on print-outs or in LARS

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HG and HR Moisture Analyzers

Chapter Overview

5 - Troubleshooting Indications from Display

5.2
5.2.1

Indications from Display


Some Pixels of the Display do not light up
Possible cause 1 Display or display drive faulty Diagnostic Remedy Replace display, see Section 6.3.12.

Error symptom Some pixels of the display do not light up

5.2.2

Temperature Indication rises above 205 C


Possible cause 1 Faulty temperature sensor Diagnostic Check Remedy Replace temperature sensor, see Section 6.3.7.

Error symptom Temperature indication rises above 205 C

2 Faulty power supply board 3 Faulty CPU board

Check Check

Replace power supply board, see Section 6.3.16. Replace CPU board, see Section 6.3.12.

5.2.3

Unstable Weight Indication


Possible cause 1 Soiled weighing cell Diagnostic Check Remedy Clean weighing cell.

Error symptom Unstable weight indication (repeatedly Error 1), poor repeatability of measurement results, or temperature jumps

2 Fatigue breakage of sample chamber cable (usually the gray colored version)

Check

Check cable and replace if necessary, see Section 6.3.22.

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5 - Troubleshooting Indications from Display

5.2.4

Hysteresis
Possible cause Support bushing of the sample pan carrier catches in hole of sample chamber front Diagnostic Check Remedy Properly position weighing cell in sample chamber chassis, see Section 6.4.1.

Error symptom Hysteresis

5.2.5

System Errors
Possible cause Memory error Diagnostic Undefined system errors Remedy Clear RAM Disconnect power. Press and hold the reset key while reconnecting the power. Display shows RAM lost. Manually enter customer settings. If the error persists, replace CPU PCB, see Section 6.3.12.

Error symptom System errors

5.2.6

Error Messages

Error messages are dealt with in the Operating Instructions. Only Error 9 asks for intervention by a Service Technician.
Error symptom Error 9 Possible cause Memory error Diagnostic Undefined system error Remedy Clear RAM Disconnect power. Press and hold the reset key while reconnecting the power. Display shows RAM lost. Manually enter customer settings. If the error persists, replace CPU PCB, see Section 6.3.12.

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6 - Repair

Repair
List of Contents
6.1 6.1.1 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8 6.3.9 6.3.10 6.3.11 6.3.12 6.3.13 6.3.14 General Instructions for Repair . . . . . . . . . . . . . . . 6-2 ESD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Preparation Work for Component Replacement . 6-3 Remove / Install the Dryer Unit . . . . . . . . . . . . . . . . . 6-3 Remove / Install the Top Housing . . . . . . . . . . . . . . . 6-4 Remove / Install Sample Chamber . . . . . . . . . . . . . . 6-5 Remove / Install the Dryer Unit Support . . . . . . . . . . 6-6 Remove / Install the Front Air Duct . . . . . . . . . . . . . . 6-8 Remove / Install the Power Supply Screening Plate . 6-9 Replacing Unit Components . . . . . . . . . . . . . . . . 6-10 Protective Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Halogen Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Left or Right Contact or Over-Temperature Switch . 6-13 Replacing Printing Unit or Printer Board . . . . . . . . . 6-14 Replacing the Membrane Keypad . . . . . . . . . . . . . . 6-16 Replacing the Top Housing . . . . . . . . . . . . . . . . . . . 6-17 Replacing the Temperature Sensor. . . . . . . . . . . . . 6-18 Replacing the Contact Block Housing or the Contact Block or Rear Air Duct . . . . . . . . . . . . . . . . 6-19 Replacing the Fan . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21 Replacing the Pivot Bearings . . . . . . . . . . . . . . . . . 6-22 Replacing the Level . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Replacing the CPU PCB . . . . . . . . . . . . . . . . . . . . . 6-24 Replacing the Program EPROM . . . . . . . . . . . . . . . 6-25 Replacing the rechargeable battery. . . . . . . . . . . . . 6-25 6.3.15 6.3.16 6.3.17 6.3.18 6.3.19 6.3.20 6.3.21 6.3.22 6.3.23 6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.5 6.5.1 6.5.2 6.5.3 6.5.4 6.6 6.6.1 Replacing the Backlighting . . . . . . . . . . . . . . . . . . . Replacing the Power Supply PCB . . . . . . . . . . . . . Replacing Heat Shield or Sample Chamber Front . Replacing the Sample Chamber Drive . . . . . . . . . . Replacing the Gear Rack . . . . . . . . . . . . . . . . . . . . Replacing the Guide Rails . . . . . . . . . . . . . . . . . . . Replacing the Guide and Supporting Rollers . . . . . Replacing the Sample Chamber Cable. . . . . . . . . . Replacing the Bottom Housing . . . . . . . . . . . . . . . . Weighing cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Weighing Cell. . . . . . . . . . . . . . . . . . Replacing Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Guides . . . . . . . . . . . . . . . . . . . . . . . Replacing the Lever . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Detector . . . . . . . . . . . . . . . . . . . . . . Weighing Cell Adjustments . . . . . . . . . . . . . . . . . Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eccentricity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Level Zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 6-27 6-29 6-30 6-31 6-32 6-33 6-34 6-35 6-36 6-36 6-39 6-40 6-41 6-43 6-44 6-44 6-45 6-46 6-48

Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Thermal Overload . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49

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6 - Repair General Instructions for Repair

6.1

General Instructions for Repair


WARNING Electrical shock hazard Unplug power supply cable before disassembly.

6.1.1

ESD
WARNING Electrostatic sensitive devices. Always use antistatic kit when working on electronic components. When removing and installing the Weighing cell, do not touch detector board and cable contacts. If no workplace with ESD protection is available, always touch the bottom housing or any other metal part of the balance before any contact with the electronics. Following this action, the board and the balance are at the same electrical potential as the person performing the work. Boards which are returned for repair must be packaged in the original antistatic packaging regardless of the fault. EEPROMs kept outside the balance must be stored on conductive foam. If soldering work is performed on the boards, a soldering iron isolated from the power supply (isolating transformer) is recommended.

Components which are sensitive to electrostatic discharge are marked with an ESD protection symbol.

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6.2
6.2.1

Preparation Work for Component Replacement


Remove / Install the Dryer Unit
Removal WARNING Allow dryer unit to cool before disassembly!

2 3

Open sample chamber (when closed, the sample chamber mechanically blocks the dryer unit), then swing open dryer unit. Disengage hinge (turn the two yellow closure levers at the left and right 90 forward). Withdraw dryer unit forward.

Installation Install the dryer unit in reverse dismantling order.

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6.2.2

Remove / Install the Top Housing


Removal 1 2 3 4 5 Push instrument a few centimeters over the edge of the bench to unscrew the 3 screws (a) in the bottom housing. Dismantle dryer unit, see Section 6.2.1. Unscrew screws (b) in the top housing (the one on the right is in the printer compartment). Retract printer paper. Lift off top housing, disconnect keypad cable and remove top housing.

Installation 1 2 Connect keypad cable to CPU board. Do not kink cable! Mount top housing horizontally from above so that the fan gasket lies precisely between the guide ribs. Fasten with the 2 screws (b) from above and the 3 plastic screws (a) from below. Thread printer paper through. Install dryer unit, see Section 6.2.1.

a
3 4

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6.2.3

Remove / Install Sample Chamber


Removal 1 Open sample chamber. 2 Remove sample pan support with sample pan and sample pan holder. 3 Unscrew switch vane (a). 4 Carefully withdraw sample chamber (ribbon cable connection) until the ribbon cable is visible. 5 Disconnect ribbon cable connector and withdraw sample chamber completely.

Installation Note: It may be necessary to grease the axles of the supporting and guide rollers as well as the slide rails of the rear air duct. Ensure that the roller faces and their guide rails remain free from grease. (Special grease for plastic; service case). 1 2 3 Connect ribbon cable. Push in sample chamber and insert rear air duct into front one. Screw switch vane in the middle of the oblong holes (if the sample chamber can be heard to touch something during motorized closure, position switch vane farther back in the long holes). Lift up sample chamber drive a short way and screw in place so that the meshing of the pinion in the gear rack is free from play.

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6.2.4

Remove / Install the Dryer Unit Support


Removal 1 2 3 4 5 6 7 Remove top housing, see Section 6.2.2. Remove temperature sensor, see Section 6.3.7. Remove fan, see Section 6.3.9. Remove cables from dryer unit support. Unscrew sample chamber drive (a). Remove sample chamber, see Section 6.2.3. Unscrew dryer unit support (b), turn carefully to the right and take off.

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Installation 1 2 3
b

4 5

6 7 8 9 10

c a

Screw on dryer unit support (b) using the two left screws and the right rear screw (do not tighten the screws). Install dryer unit, see Section 6.2.1. Now move closed dryer unit together with the dryer unit support so that the dryer unit lies against the left side of the bottom housing. Then tighten the two rear screws of the dryer unit support. Dismantle dryer unit, see Section 6.2.1. Tighten left, front screw of the dryer unit support. With the right front screw simultaneously tighten the rear EMC contact spring (c) (center with the rib of the bottom housing). Fix cable to the dryer unit support. Install fan, see Section 6.3.9 and temperature sensor, see Section 6.3.7. Install sample chamber drive (a). Install sample chamber, see Section 6.2.3. Mount top housing, see Section 6.2.2.

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6.2.5

Remove / Install the Front Air Duct

Removal 1 2 3 Remove sample pan support with sample pan as well as sample pan holder and draft shield. Unscrew sample chamber front and remove. Bend white plastic latches on left of air duct a short way to the left and at the same time lift up air duct at left and pull off to the left.

Installation 1 Remount air duct and engage. Do not forget the two EMC compression springs on the left and right (between air duct and sample chamber frame). Mount sample chamber front with heat shield and screw in place. Mount draft shield, sample pan holder, sample pan support and sample pan.

2 3

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6.2.6

Remove / Install the Power Supply Screening Plate

Removal 1 2 Unscrew built-in printer retaining screw on the left and lift printer out with a slight to and fro movement. Unscrew power supply screening plate and place on the left.

Installation 1 2 Screw on power supply screening plate (2 screws with washers at rear and 2 screws with washers on the right). Screw on the front EMC contact (a) spring with the fifth screw and washer. Make sure the contact is centered with the rib of the bottom housing. Insert built-in printer, connect to power supply board at the bottom and fix with screw.

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6.3
6.3.1

Replacing Unit Components


Protective Glass

Removal 1 2 Remove dryer unit, see Section 6.2.1. Remove heating module from the dryer unit as follows: With your left thumb, press the black latch hard downward and at the same time use your right thumb and forefinger to push the heating module approx. 3 mm to the left over the latch.

Use both thumbs to pull the complete heating module over the latch until you hear it disengage. Then lift it out of the dryer unit. Push protective glass with reflector to the rear and remove from the heating module.

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Installation 1 2 3 4 Insert new protective glass; the slot in the glass must lie on the side of the contacts of the halogen radiator. Insert reflector in the heating module right to the bottom. Lay down dryer unit so that the hinge points to the front. Insert complete heating module in the dryer unit so that it touches at the back (arrow).

Using the balls of the thumbs, press the heating module down hard at the left and right while simultaneously pulling it to the back with your forefingers until you hear it engage. Install dryer unit, see Section 6.2.1.

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6.3.2
a

Halogen Radiator
Removal 1 2 3 4 Dismantle dryer unit, see Section 6.2.1. Dismantle protective glass, see Section 6.3.1. Pull off the two connectors (a) of the halogen radiator using flat-nose pliers. Use both forefingers to spread the retaining spring (b) to the left and right and at the same time use both thumbs to lift the halogen radiator upward out of the retaining spring (the two ends of the halogen radiator must not be bent toward each other or apart, otherwise the glass tube will break).

c c

Installation Attention Touch only the black part of the halogen radiator! If necessary, clean with weak organic solvent. Hold the new halogen radiator by the black ends and insert it into the two metal supports (c) at the back. Place the flat connector side of the halogen radiator on the retaining springs at the front, use both thumbs to press it about 2 mm to the back against the metal support plates and then down to engage in the clamping springs. Reconnect the 2 connectors of the halogen radiator. Install the protective glass, see Section 6.3.1. Install the dryer unit, see Section 6.2.1.

5 6

7 8 9

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6.3.3

Left or Right Contact or Over-Temperature Switch


1 2 3 Open sample chamber, then swivel upwards the dryer unit. Pull off relevant cable connector using flat-nosed pliers. Replace left or right contact (e) or over-temperature switch (d). Do not forget spacing washer (c) on heat conducting plate (a)! Tighten nut (b) to 1.2 Nm. Warning The right-hand connector of the switch and the connector of the left-hand contact plate must not touch each other! After replacing the over-temperature switch, perform a heater test using LARS.

c a

4
a b d

If over-temperature switch has responded, reset with finger (do not push spring under edge of base!).

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6.3.4

Replacing Printing Unit or Printer Board


Removal 1 2 3 4 Swing open printer cover. Pull paper out of printing unit. Remove printer retaining screw at left. Remove model strip: disengage by pulling up at left, pull off to the left. Carefully pull built-in printer up and out of the HG/HR moving it to and fro slightly.

Remove printer board as follows: disconnect printer cable, bend left and right retaining lug away from the printer board and at the same time push the printer board over the retaining lugs and remove.

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Remove printing unit from printer support as follows: on the ribbon side, bend left retaining lug away from the metallic printing unit base plate and at the same time press the printing unit on the board side so that the printing unit base plate is shifted about 0.2 mm over the retaining lug. in the same way, push the printing unit base plate over the right retaining lug. push the printing unit fully out of the printer support from the board side.

Installation The installation of the built-in printer follows the revers dismantling order. Make sure to have ready a new printing unit or new printer board, place EMC spring (a) and engage printing unit in the printer support. Attention Carefully insert the printer in the HG/HR to prevent the pins in the connector on the power supply board from being bent! Never insert the printer at an angle!

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6.3.5

Replacing the Membrane Keypad

1 2 3

Remove the top housing, see Section 6.2.2. Strip off damaged membrane keypad from the cable side. Remove residual adhesive (if necessary, use pure benzene). Caution Benzene is highly inflammable, use only small quantities. Insert the cable of the new membrane keypad. Pull off the cover sheet of the adhesive layer. Fit the membrane keypad into the recess of the top housing, first only at the left, front corner and then at the left edge. Then roll into the recess to the right and press in place. Install the top housing, see Section 6.2.2.

4 5 6

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6.3.6

Replacing the Top Housing

a c

1 2

Remove the top housing, see Section 6.2.2. Transfer the level cover (a), the model strip (b) and the printer cover (c) from the damaged top housing to the new one. Install the top housing, see Section 6.2.2.

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6.3.7

Replacing the Temperature Sensor


1 2 3 Remove the top housing, see Section 6.2.2. Cut cable fastener of sensor cable and pull off connector. Lift temperature sensor out of the contact block housing (bend out the white retaining clips forward slightly) and replace. Please note: the cable must lead in a straight line from the temperature sensor backward to the cable clip and the EMC contact spring must press against the temperature sensor. Plug in connector and attach new cable fastener. Install the top housing, see Section 6.2.2. Connect instrument to the power supply. Adjust temperature as described in the short-form operating instructions of the Moisture Analyzer. If the message Error 5 appears, use LARS to clear temperature calibration data and to adjust dryer unit again.

4 5 6 7

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6.3.8

Replacing the Contact Block Housing or the Contact Block or Rear Air Duct

a
Removal 1 2 3 Remove top housing, see Section 6.2.2. Remove dryer unit support, see Section 6.2.4. Unscrew the two screws (a) of the rear air duct (Attention: hold nuts when removing the screws!) and remove the rear air duct. Unscrew four screws (b) of the contact block housing and remove housing and contact block.

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Installation Note: If components carrying power supply voltage have been removed and reinstalled, check for correct ground connection: Make sure the grounding screws are tightly fastened with a toothed washer in the correct place. Make sure there is a low-resistance connection between the ground pin of the power supply plug and the grounded housing parts. Make sure there is a direct connection from the ground pin of the power supply socket to the grounding screw on the housing. Check with ohmmeter.

2 3 4 5

d
6 7 8

Fix contact block and contact block housing with the four screws (b) to the dryer unit support. Make sure the EMC contact spring (c) under the contact block is placed so, that it presses upward against the temperature sensor. Mount rear air duct with the screws and shaft nuts, but do not tighten the screws yet. Install dryer unit support, see Section 6.2.4, but do not mount the fan. Push in the sample chamber completely. Equalize horizontal play between the rear (inner) air duct and the front (outer) air duct and check by inserting a paper strip (d) of thickness approx. 0.2 mm at the left and right of the fan under the inner air duct. Screw in the two screws of the rear air duct (hold nuts). Insert fan from above in its holder. Mount top housing, see Section 6.2.2.

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6.3.9

Replacing the Fan

1 2 3 4 5 6

Remove top housing, see Section 6.2.2. Remove CPU screening plate to access the fan connector. Disconnect fan connector at the CPU board and remove cable from the cable clips. Pull fan up and out of the holder. Install new fan. Ensure that the gasket exactly encircles the fan. Mount top housing, see Section 6.2.2.

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6.3.10 Replacing the Pivot Bearings


a

1 2 3 4 5

Remove top housing, see Section 6.2.2. Unscrew faulty pivot bearings (yellow closure levers (a) can be taken over). Screw left and right pivot bearing in lowest position. Install dryer unit, see Section 6.2.1. Swing down dryer unit and check that it is horizontal and flush with the top housing. If need be, screw pivot bearings in a higher position. Mount top housing, see Section 6.2.2.

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6.3.11 Replacing the Level

1 2 3 4 5 6 7 8

Remove top housing, see Section 6.2.2. Replace faulty level (a) by a new one (use the 3 screws to tension slightly on the spring washers, but do not level yet). Dismantle sample chamber, see Section 6.2.3. Place service level under the dryer unit support in the bottom housing. Adjust the three leveling feet until the air bubble of the service level is in the center. Remove service level and adjust level on the dryer unit support until its air bubble is in the center. Install sample chamber, see Section 6.2.3. Mount top housing, see Section 6.2.2.

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6.3.12 Replacing the CPU PCB


Removal 1 Switch on HG/HR and store or print out cell parameters, methods and user configuration with the aid of LARS (if necessary and possible). 2 Switch off instrument and disconnect from power supply! 3 Remove top housing, see Section 6.2.2. 4 Unscrew CPU screening plate. 5 Unscrew CPU board. 6 Carefully disconnect the 3 connectors of the fan, weighing cell and power supply board. 7 Carefully remove the program EPROM (a) from the old and insert in new CPU board, casing notch points to the left. Installation
a

Install in reverse order. After replacing the CPU board, reload cell parameters, methods and user configuration or key in from cell parameter strip (affixed to the CPU screening plate). Important Note A CPU PCB which was previously installed in another instrument (e.g. for 'trial and error') will cause a wrong instrument designation on print-outs or in LARS, and must be reset as follows: Disconnect keyboard. Connect instrument to the power. Short-circuit keyboard connector pins 6 and 8 (counted from left). Produktion is displayed. The PCB can be re-used.

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6.3.13 Replacing the Program EPROM


Removal 1 2 3 Remove top housing, see Section 6.2.2. Unscrew CPU screening plate. Carefully pull off old program EPROM.

Installation The installation follows the reverse dismantling order. When inserting the new program EPROM make sure the casing notch points to the left.

6.3.14 Replacing the rechargeable battery


Removal 1 2 3 Remove top housing, see Section 6.2.2. Remove CPU board, see Section 6.3.12. Unsolder the rechargeable battery.

Installation The installation follows the reverse dismantling order. Solder in new battery as shown in the opposite figure.

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6.3.15 Replacing the Backlighting

1 2 3 4

6 7 8 9

Remove top housing, see Section 6.2.2. Unscrew CPU screening plate. Unsolder connection leads of the backlighting from the soldering lugs on the CPU board. Unscrew screws of the CPU board to an extent which prevents the backlighting touching the dryer unit support when removed at the left. Push in new backlighting so that the transparent surface faces upward and that it is fully held by the display holder on the right. Tighten screws of the CPU board. Solder in connection leads of the backlighting. Screw on CPU screening plate. Mount top housing, see Section 6.2.2.

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6.3.16 Replacing the Power Supply PCB


b

Removal 1 2 3 4 5 6 Dismantle CPU PCB, see Section 6.3.12. Remove power supply screening plate, see Section 6.2.6. Unscrew sample chamber drive (a) and place to one side. Unscrew eye (b) of protective ground cable of the power receptacle. Unplug the 2 connectors of the sample chamber drive and the halogen radiator. Unscrew power supply board and remove.

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Installation NOTE: If components carrying power supply voltage have been removed and reinstalled, check for correct ground connection: Make sure the grounding screws are tightly fastened with a toothed washer in the correct place. Make sure there is a low-resistance connection between the ground pin of the power supply plug and the grounded housing parts. Make sure there is a direct connection from the ground pin of the power supply socket to the grounding screw on the housing. Check with ohmmeter.

a
3 4 5

Screw in new power supply board (3 screws with toothed lock washer beneath screw head, 4th screw at left front without toothed lock washer). Screw on eye (b) of the protective ground cable of the power receptacle (toothed lock washer beneath screw head). Connect sample chamber drive and halogen radiator. Install power supply screening plate, see Section 6.2.6. Install CPU PCB, see Section 6.3.12.

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6.3.17 Replacing Heat Shield or Sample Chamber Front


1 2 3 4 5 6 Open sample chamber. Remove sample pan support with sample pan as well as sample pan holder and draft shield. Unscrew sample chamber front (a). Lift up heat shield (b) slightly at front and then lift up and out towards rear. Replace heat shield or sample chamber front. Screw on sample chamber front, mount draft shield, sample pan holder as well as sample pan support with sample pan.

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6.3.18 Replacing the Sample Chamber Drive

1 2 3 4

5 6 7 8

Remove CPU board, see Section 6.3.12. Remove power supply screening plate, see Section 6.2.6. Unplug connector of sample chamber drive and remove sample chamber drive. Screw on new sample chamber drive loosely (toothed lock washer beneath screw head), then raise it so that the meshing of the pinion in the gear rack is free from play and tighten screws. Plug in connector of the sample chamber drive. Install power supply screening plate, see Section 6.2.6. Install CPU board, see Section 6.3.12. Insert built-in printer, carefully plug into connector on the power supply board at the bottom and tighten screw.

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Chapter Overview

6 - Repair Replacing Unit Components

6.3.19 Replacing the Gear Rack

Note: If the teeth of the gear rack (a) on the right are damaged, they can be exchanged with those on the left. 1 2 3 4 5 6 7 8 9 a Remove sample pan support with sample pan as well as sample pan holder. Remove top housing, see Section 6.2.2. Dismantle sample chamber, see Section 6.2.3. Dismantle front air duct, see Section 6.2.5. Disengage damaged gear rack and replace. Install front air duct, see Section 6.2.5. Install sample chamber, see Section 6.2.3. Mount top housing, see Section 6.2.2. Insert sample pan holder and sample pan support with sample pan.

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6 - Repair Replacing Unit Components

6.3.20 Replacing the Guide Rails

1 2 3 4

Remove dryer unit support, see Section 6.2.4. Remove faulty guide rails. When screwing on the new guide rails, press the left guide rail to the left, the right guide rail to the right. Install dryer unit support, see Section 6.2.4.

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6 - Repair Replacing Unit Components

6.3.21 Replacing the Guide and Supporting Rollers

rs lle o R ing t r o pp Su

1 2 3

4 5

Remove top housing, see Section 6.2.2. Dismantle sample chamber, see Section 6.2.3. Replace guide and supporting rollers. Note: Upper rollers with bearings, lower rollers without bearings. Install sample chamber, see Section 6.2.3. Mount top housing, see Section 6.2.2.

ers oll R ide Gu

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Chapter Overview

6 - Repair Replacing Unit Components

6.3.22 Replacing the Sample Chamber Cable


1 2 3 4 Dismantle CPU board, see Section 6.3.12. Dismantle power supply screening plate, see Section 6.2.6. Dismantle sample chamber, see Section 6.2.3. Replace sample chamber cable. Please note: Carefully fold cable so that it touches nothing when the sample chamber is closed. Position cable support clip near the left rear leveling screw so that it is not pinched between the cable board and rear panel of the bottom housing when the sample chamber is closed. Install sample chamber, see Section 6.2.3. Install power supply screening plate, see Section 6.2.6. Install CPU board, see Section 6.3.12.

5 6 7

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Chapter Overview

6 - Repair Replacing Unit Components

6.3.23 Replacing the Bottom Housing


Removal 1 2 3 4 5 6 Dismantle CPU board, see Section 6.3.12. Dismantle power supply screening plate, see Section 6.2.6. Dismantle power supply board, see Section 6.3.16. Dismantle dryer unit support, see Section 6.2.4. Dismantle guide rails, see Section 6.3.20. Remove leveling screws. Installation NOTE: If components carrying power supply voltage have been removed and reinstalled, check for correct ground connection: Make sure the grounding screws are tightly fastened with a toothed washer in the correct place. Make sure there is a low-resistance connection between the ground pin of the power supply plug and the grounded housing parts. Make sure there is a direct connection from the ground pin of the power supply socket to the grounding screw on the housing. Check with ohmmeter. 1 2 Mount the leveling screws in the new bottom housing. Affix rating plate and information plate (the plates were destroyed when the old bottom housing was removed, they must therefore be reordered with details of the serial number). Screw on guide rails, see Section 6.3.20. Install power supply board, see Section 6.3.16. Install dryer unit support, see Section 6.2.4. Plug in connector of the sample chamber drive and the connector of the radiator cable. Install power supply screening plate, see Section 6.2.6. Install CPU board, see Section 6.3.12. Do not forget: plug in the 3 connectors for the fan, weighing cell and power supply board.

3 4 5 6 7 8

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Chapter Overview

6 - Repair Weighing cell

6.4
6.4.1

Weighing cell
Replacing the Weighing Cell
Removing 1 2 3 4 5 6 Remove top housing, see Section 6.2.2. Remove sample chamber, see Section 6.2.3. Remove front air duct, see Section 6.2.5. Unplug the two connectors at the left and right on the cover of the weighing cell screening. Lift off cover of the weighing cell screening. Disengage the two small tension springs at the weighing cell cantilever arm using the tip of a paper clip (or a clamptype test probe) and remove cantilever arm. Place the sample chamber to the side and unscrew the small Phillips screw of the weighing cell screening as well as the two larger Phillips screws of the weighing cell. Lift weighing cell together with the weighing cell screening out of the sample chamber frame.

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6 - Repair Weighing cell

Installation 1 2 3 4 5 Place weighing cell inside the screening in the sample chamber frame. Screw on weighing cell screening from below. Loosely fix the weighing cell with the two Phillips screws and conical spring washers. Push cantilever arm on the arm support and engage the two small tension springs using a paper clip. Hold weighing cell at top by its chassis and move it so that the black bearing sleeve of the cantilever arm is exactly in the middle of the sample chamber frame; at the same time ensure that a uniform air gap remains between the weighing cell and the screening (to ensure no heat bridges are formed). Tighten the two Phillips screws fixing the weighing cell. Mount cover of the weighing cell screening and plug in the two connectors on the left and right. Check the distance between the top edge of the cantilever arm and the weighing cell chassis. It must be 7.7 0.5 mm. If it is not, correct with the setscrew. Push sample chamber onto rails and connect ribbon cable. Mount adjustment weighing pan (from the service case). Use LARS to load the new cell parameters. Affix cell parameter strip to the CPU screening plate using adhesive tape.

6 7

7.7 0.5 mm

8 9 10

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6 - Repair Weighing cell

11

12

13 14 15 16 17

Test eccentricity and adjust if necessary (open sample chamber until the eccentricity screws in the cover of the weighing cell screening become visible. Then adjust these and push in sample chamber until the front rollers are again on the rails). Check that the bearing sleeve does not touch the sample chamber front: Press adjustment weighing pan right down using your finger. It must not stick and the display must show the same value after the pan is released. After adjustment of the eccentricity, disconnect instrument from the power supply again! Remove adjustment weighing pan. Install front air duct, see Section 6.2.5. Install sample chamber, see Section 6.2.3. Mount top housing, see Section 6.2.2.

Adjustments After repairing and/or replacing the measuring cell, perform Repeatability, Eccentricity, Sensitivity, Linearity.

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6 - Repair Weighing cell

6.4.2

Replacing Link
picture differs slightly from actual

c b a

Removal 1 To protect the flexible bearing at the hanger, loosely insert two screws (a) M4x25 from the service kit (2-3 turns). 2 Loosen lower link screw (b). Note: To protect the flexible bearing, hold hanger. 3 Loosen upper link screw (c). Note: Be careful not to damage the bearings. 4 Unscrew lower link screw and take out the upper screw together with the link. Installation 1 Place hanger shims (k) under hanger (adjust hanger height). 2 Insert the upper link screw together with the link from above between lever and hanger and tighten loosely. Note: The round hole of the link is at the top. The burred side of the torsion protector lies on the link. Align the link exactly vertical. 3 Insert lower link screw, but do not tighten yet. Note: Burred side of torsion protector lies on link. 4 Tighten upper link screw. 5 Press hanger onto hanger shims, tighten lower link screw (adjust hanger height). Note: When tightening the lower link screw, press the arm support (n) against the table surface so that it becomes parallel to the base of the weighing cell. 6 Remove the two service screws on the hanger.

k
n

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6 - Repair Weighing cell

6.4.3

Replacing the Guides


a

pictures differ slightly from actual

Removal 1 Loosen the bottom screws (d) of the top and bottom guides until hanger and guides move freely. 2 Slide hanger distance gauges between hanger and chassis and fix with two service screws (a). 3 Unscrew overload protection. 4 Remove top and bottom guides; the cell can be laid on the appropriate side for this. Note: Replace complete guide, i.e. with flexible bearing.

k a

Installation 1 Fix hanger loosely to chassis with service screws (a) M4x25. 2 Place hanger shims (k) under hanger and slide hanger distance gauges between hanger and chassis. Now press hanger onto hanger shims, tighten service screws (a). 3 Mount top guide (screw head to chassis). Center flexible bearings with screw holes and screw tight. 4 Mount bottom guide (screw head facing outward). Center flexible bearings with screw holes and screw tight. 5 Fasten overload protection. 6 Unscrew service screws (a) and remove hanger distance gauges.

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6 - Repair Weighing cell

6.4.4

Replacing the Lever


e f
Removal 1 Remove link, see Section 6.4.2. 2 Remove guides, see Section 6.4.3. 3 Remove hanger distance gauges and hanger. 4 Unscrew counterweight (e) (small brass plate). 5 Remove lateral stop plate (f). 6 Unsolder contact strips (g) at lever board. 7 Unscrew bearing screws (h) on chassis side, remove pressure plates, torsion protectors and spring washers. 8 Lift lever out of chassis and lay down with coil upward.

g
Replacing bearings 1 Press upper side of lever against the hanger shims, unscrew the bearings from lever. Note: Always replace both bearings. Long hole on lever side. 2 Press upper side of lever against the hanger shims (lever is horizontal!) so that the bearings are vertical to the lever. Tighten screws (M4x16) with spring washers, torsion protectors and pressure plates.

90

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6 - Repair Weighing cell

Installation Bearings checked or replaced. 1


picture differs slightly from actual

e
2

f
3

6 7

Place lever in chassis and insert screws (h) (M4x16) with spring washers, torsion protectors and pressure plates in bearings, but do not tighten yet. Slide lever gauge (i) between lever and chassis. Note: Gauge must not lie against the locking nut of the level weight. Mount counterweight (e) on lever (tighten loosely) and ensure that no pressure is exerted on bearings. Press down lever on bearing side, tighten screws. Note: Center holes of bearings with the thread in the chassis. Center the detector vane of the lever with detector. Mount lateral stop (f) (M3x6). Note: Center peg at lever with engagement hole. Check by lateral pressure on the lever. Tighten fastener screw at counterweight. Solder on contact strips at lever board. Note: The strips must be parallel, they must not touch. Assemble instrument.

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6 - Repair Weighing cell

6.4.5

Replacing the Detector

Removal 1 Disconnect cable from detector board. 2 Unsolder both temperature sensor wires (n). 3 Unscrew detector housing with detector board. Installation

n m

Requirements: The reference resistor (m) of the defective detector must be transferred to the replacement detector or a new resistor ordered. 1 2 Plug connection cable to detector board. Screw detector board to magnet system. Note: The detector housing is parallel to the underside of the lever and is centered. Solder on the two temperature sensor wires (n) (polarity not important).

picture differs slightly from actual

Adjustments of detector board see Section 6.5.2.

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6 - Repair Weighing Cell Adjustments

6.5

Weighing Cell Adjustments

General information Before every adjustment, check that the weighing cell is mechanically in order. Test weights and tolerances see Chapter 9. Replacing the Weighing Cell see Section 6.4.1.

6.5.1

Hysteresis

Press weighing pan down firmly until full load, release. Tare. Using a brush, raise weighing pan slightly and press down slightly. The balance display must return to zero in all cases. If this is not the case, check the weighing cell for mechanical faults or dirt in the magnet system.

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6 - Repair Weighing Cell Adjustments

6.5.2

Detector
Notes If the detector board is out of adjustment or has been replaced, it must be realigned. It is necessary to expose the weighing cell for this.
14.7 0.1 mm top of screw to bottom of chassis

The vertical stop setting is the reference for the lever height (horizontal position). Starting position 14.7 0.1 mm (see illustration). Preparation Ribbon cable from the detector board connected, coil cable disconnected. Plug service cable to detector board and attach the voltmeter (DC range). Switch on balance. Determining voltage value Note down 1st voltage value U1 as soon as the balance is switched on. The lever is at the bottom of the vertical stop. Press down the hanger until the lever is at the top of the vertical stop. Note down 2nd voltage value U2. If the two voltage values U1 and U2 are different, (e.g. +2 V/-1.6 V), move the detector housing downward or upward until U1 and U2 are the same. Remark:

picture differs slightly from actual

Voltage range 1.5 V...3 V Asymmetry max. 0.1 V

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6 - Repair Weighing Cell Adjustments

6.5.3

Eccentricity

The principle of the eccentricity error correction involves setting the parallelism of the parallelogram formed by the upper and lower guides by adjusting the rear fixing points of the upper guide. Checking the basic setting The following applies as the basic setting or for a visual check on the eccentricity and setscrew. The bottom of the slot in the setscrew is flush with the upper edge of the eccentricity screw. The distance at the rear of the chassis, where the eccentricity spring is press fitted, is 4.5 0.1 mm (see illustration). The setscrew must not turn. If so, tighten locking nut.

4.5

0.1

mm

Preparation Install measuring cell, connect all cables. Close instrument, mount adjustment pan (service case). Switch on instrument.

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6 - Repair Weighing Cell Adjustments

Example

-10

0 +3 +7 -2

Eckenlast

Correcting the eccentricity error 1 Place test weight in the middle of the weighing pan and tare. 2 Move weight to left, rear, right and front to the edge of the weighing pan and note down/print out display values with sign that differ from zero (see example). 3 Compare display values with eccentricity tolerances in Section 9.1.

Correct deviations by turning the eccentricity screws in the direction of the arrow, as shown in the illustrations.

Notes Combine correction of longitudinal and transverse errors. Turn the eccentricity screws using a 6 mm socket wrench.

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6 - Repair Weighing Cell Adjustments

6.5.4

Level Zero

If the measuring cell has been completely dismantled, the leveling weight must be adjusted using the leveling screw. 1 2 3 4 Level instrument. Tare instrument with empty weighing pan. Lift balance at front and insert 0.5 mm shim (metal ruler) under the front feet. Correct by turning screw (a). Tolerance values according to tolerance table, Section 9.2. If the display value is negative (-), turn screw (a) in. If the display value is positive (+), turn screw (a) out. Example:
Level indicator adjusting the leveling screw

Display -

5 6

Remove shims. Tare again with empty weighing pan.

Repeat this procedure (Steps 4 - 6) until the two values (with / without shim) lie within tolerance.

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6 - Repair Tests

6.6
6.6.1

Tests
Thermal Overload
Purpose To test the Temperature Limit Switch for correct functioning.

1
Heater Test

Procedure 1 Open dryer unit and clean protective glass and reflector in the heating unit to avoid heat absorption. 2 Bend the white holder (1) slightly forward and remove the temperature sensor. 3 Turn temperature sensor around and push it to the back (2) so it does not become trapped when the dryer unit is closed. 4 Use new aluminum sample pan for max. heat reflection. 5 Close the dryer unit.

In LARS, open the Text menu and click Thermal overload. Perform Test as described in the LARS Help menu (F1).

WARNING Allow heating module to cool down!

Reset Temperature Limit Switch (3).

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7 - LARS

LARS
List of Contents
7.1 7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.4 7.4.1 7.4.2 LARS - LabTec Repair and Service Software . . . . 7-2 LARS Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Software-Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Download from Internet . . . . . . . . . . . . . . . . . . . . . . . 7-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 TDNR File Update . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Using LARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Connect balance to computer . . . . . . . . . . . . . . . . . . 7-9 Start / Exit LARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Working with LARS . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Load type data (TDNR) . . . . . . . . . . . . . . . . . . . . . . 7-11 Data Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Consequences. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

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7 - LARS LARS - LabTec Repair and Service Software

7.1

LARS - LabTec Repair and Service Software


Operating instructions The LARS Operating Instructions are part of the software, i.e. an integrated help file. Press the F1 key or select the Help Menu.

LARS is a Service SW to verify, repair and diagnose PRODUCTs. It is available in the four languages German, English, French and Spanish. to verify means to remeasure the technical data and to compare these measured data with the nominal values listed in the tolerance table. to repair means to replace parts and configure the balance as to restore it to the original working order, i.e. a state in which it can perform the specified performance. to diagnose means to perform a test to conclude from symptoms/results whether a suspicious behavior is confirmed or not.

Operating system requirements LARS <V1.80 runs on any PC under Windows 95/98/NT/XP. LARS V1.80 runs under Windows XP Professional only.

LARSLock Hardlock (usage protection) required to run the service software. Part no. see Chapter Service Aids. LARS SW availability Find the LARS Service Software on the Service Expert DVD. However, to make sure to always have the latest version, download it from the LabTec Homepage http://www.extranet.mt.com.

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Chapter Overview

7 - LARS LARS Installation

7.2
7.2.1

LARS Installation
Requirements
ATTENTION Before you install LARS from the ServiceExpert disc, please check on http://www.extranet.mt.com whether you have the latest version of the LARS software. If you are not authorized to install SW, ask your IT support.

Mettler-Toledo recommends to work with the latest version of LARS. See Section 7.2.3 as how to install it. USB hardlock LARSLock 11107505. , part number

7.2.2

Software-Check
1 2 Double-click . Click Help A and then click Info.

The About LARS window opens. The currently installed version B is displayed. B

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7 - LARS LARS Installation

7.2.3

Download from Internet

1 2 3

Click on the link http://www.extranet.mt.com (LabTec Market Support). Click LabTec Market Support. Enter user name and password. If password is not available, ask your Service Manager.

4 5

Click Software. Click LARS Software. The most recent version of the LARS software is shown at the top of the list.

Click on the software version you wish to download.

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7 - LARS LARS Installation

Click Installation.

Click Run.

10 9

9 10

The storage location is displayed. Accept (recommended) or select one suiting your system organization. Click Unzip. The files are saved in the selected storage location.

11

11

Click OK.

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7 - LARS LARS Installation

7.2.4

Installation

Run Setup.exe. The installation procedure starts. Follow the instructions of the installation program.

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7 - LARS LARS Installation

7.2.5

TDNR File Update


Note: Frequently check the content version.

1 2 3 4

Exit LARS. Click on the link http://www.extranet.mt.com (LabTec Market Support). Click LabTec Market Support. Enter user name and password. If password is not available, ask your Service Manager.

5 6

Click Software. Click LARS TDNR File. TDNR file version

Click the LARS TDNR type data link.

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7 - LARS LARS Installation

8 8

Click Run.

Click Run. The storage location is displayed. Accept (recommended) or select one suiting your system organization.

10

10

Unzip saves the file in the selected storage location.

11

Click OK.

11

12

Start LARS and check TDNR file version, see Section 7.3.4.

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7 - LARS Using LARS

7.3
7.3.1

Using LARS
Connect balance to computer
1 2 Connect the instrument to the COM port of the computer. Connect the LARSLock to the computer.

Find Ordering Information for LARS SW, LARSLock and Cables in Chapter Service Aids.
LARSLock USB

7.3.2

Start / Exit LARS


Start Start > All Programs > double-click .

The LARS menu window appears. All further work with LARS is selected in the various popup menus. Exit File > Exit

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7 - LARS Using LARS

7.3.3

Working with LARS

LARS Operating Instructions The LARS functions are described in detail in the LARS-help. Press F1 to open the Help window shown on the left:

The Help key F1 can be pressed again for each operation. The Help function explains the current situation.

Example:

Click on a Menu.

Point to a menu item.

F1

Press F1.

The Help page for the corresponding menu item opens.

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7 - LARS Using LARS

7.3.4

Load type data (TDNR)


WARNING If new type definition is loaded, it must be entered on the service label of the corresponding device. Hinweis: Check for the latest TDNR file Content Version, update if necessary. See Section 7.2.5. The TDNR on the type plate of the device corresponds to the state at the initial shipping. Firmware or hardware changes may make it necessary to load the new TDNR in line with the new functionalities.

1 2 3 4 5

LARS main menu: Data > Type Definition. Enter the device type or the TDNR. Select the exact type. Select the appropriate TDNR. Click Load.

TDNR file version

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7 - LARS Data Handling

7.4
7.4.1
TDNR

Data Handling
Terminology
Program of Moisture Analyzer Type Definition Number Adjusting User Settings Correct deviations of measurement results Menu settings set by user (stored on CPU board)

Firmware

Cell parameters Temp. compensation data and parameters to run measuring cell

7.4.2

Consequences
Impact on firmware and data
Device firmware and TDNR applications Permanently stored in PROM on CPU board. Cell parameters Adjusting User settings

When replacing

CPU board

Check version, if nec- Load using LARS essary change EPROM. no impact Load using LARS

Key in cell parameters Adjust LIN and CAL from paper strip

Type in manually

Weighing cell

Key in cell parameters Check, if necessary No impact from paper strip carry out LIN and CAL

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8 - Adjusting in the Service Menu

Adjusting in the Service Menu


The adjustment of the HG/HR moisture analyzers is performed via the LARS software since the HG/HR moisture analyzers do not have a special service mode menu. To perform an adjustment you have to proceed as follows: 1 2 3 Connect HG/HR moisture analyzer to a PC via the special LC-RS9 cable, settings 1-3-0. Start LARS software on PC. Start HG/HR moisture analyzer in Service Mode: HR73/HR83 and HG53/HG63: Press and hold , then press simultaneously for approx. 4 sec. to start the service mode. HG-F: Press and hold , then press simultaneously for approx. 4 sec. to start the service mode. Perform the necessary adjustments according to the LARS software (see Section 7).

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9 - Adjustment Data

Adjustment Data
List of Contents
9.1 9.2 Eccentricity, Repeatability, Linearity, Sensitivity. 9-2 Level adjustment, Drawer in/out, Temperature . . 9-3

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9 - Adjustment Data Eccentricity, Repeatability, Linearity, Sensitivity

9.1
Type Range Class HG53 1 l HG63 1 l HG-F 1 l HR73 1 l HR83 1 l

Eccentricity, Repeatability, Linearity, Sensitivity


Eccentricity Method Refer. weight Tolerance 50 g 1 mg 50 g 1 mg 50 g 1 mg 50 g 1 mg 50 g 1 mg Repeatability Method Refer. weight Measurements Std. deviation max. 50 g 6 0.5 mg 50 g 6 0.5 mg 50 g 6 0.5 mg 50 g 6 0.5 mg 50 g 6 0.5 mg Linearity Method Preload Refer. weight Tolerance 10/20/30/40 g 10 g 1 mg 10/20/30/40/50 g 10 g 1 mg 20/40/60 g 20 g 1 mg 10/20/30/40/50/60 g 10 g 1 mg 20/40/60 g 20 g 1 mg Sensitivity Method Refer. weight Class Tolerance 50 g E2 1 mg 60 g E2 1 mg 80 g E2 2 mg 70 g E2 1 mg 80 g E2 1 mg Capacity Readability d e 51 g 1 mg 1 mg 61 g 1 mg 1 mg 81 g 1 mg 1 mg 71 g 1 mg 1 mg 81 g 1 mg 1 mg

Balance Data

E2

E2

E2

E2

E2

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9 - Adjustment Data Level adjustment, Drawer in/out, Temperature

9.2
Type Range Class HG53 1 l HG63 1 l HG-F 1 l HR73 1 l HR83 1 l 1) 2) 3)

Level adjustment, Drawer in/out, Temperature


Zero point deviation 1) Method Refer. weight front/rear Sample chamber drawer Method weight difference in/out Temperature 2) 3) Moisture Temp. 50 C Moisture Temp. 100 C Moisture Temp. 160 C 3 C 3 C 3 C 3 C 3 C 3 C 3 C 3 C 3 C 3 C 3 C 3 C 3 C 3 C 3 C Capacity Readability d e 51 g 1 mg 1 mg 61 g 1 mg 1 mg 81 g 1 mg 1 mg 71 g 1 mg 1 mg 81 g 1 mg 1 mg

Balance Data

0g 2 mg 0g 2 mg 0g 2 mg 0g 2 mg 0g 2 mg

2 mg

2 mg

2 mg

2 mg

2 mg

Place 0.5 mm shim (e.g. metal ruler) under front feet (zero point deviation left/right can not be adjusted). Observe thermometer graduation: 1 graduation mark = 2 C! Use the HA-TCC Calibrated Temperature Adjustment Set

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HG and HR Moisture Analyzers

Chapter Overview

10 - Accessories

10

Accessories
All accessories for the HG and HR moisture analyzers are listed in the Technical Data and Accessories chapter of the corresponding Operating Instructions. There you will also find the necessary ordering information. Find the Operating Instructions on the LAB ServiceExpert DVD or at http://www.extranet.mt.com LabTec Market Support.

Frequently used accessories


Designation Protective Cover (set of 2) Mains cable Note HA-COVER DK GB USA AUS SA EU (Schuko) CH I HA-TC HA-TCC HA-CAGE Part No. 00214533 00087452 00089405 00088668 00088751 00089728 00087925 00087920 00087457 00214455 00214528 00214695

Temperature calibration kit (in box with thermometer) Temperature calibration kit (in box with certified thermometer) Weighing pans for bulky samples

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HG and HR Moisture Analyzers

Chapter Overview

11 - Service Aids

11

Service Aids
Designation LARS Software Download the latest version of the LARS Software from http://www.extranet.mt.com LabTec Market Support Part No. --------

USB-Dongle LARSLock

11107505

ServiceExpert DVD

11780410

Screwdriver set

11600675

ESD Service-Kit

11600009

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HG and HR Moisture Analyzers

Chapter Overview

11 - Service Aids

Adjustment pan

00214674

Eccentricity wrench 6 mm Service gauge HG/HR 1 Lever gauge 2 Hanger distance gauges 2 Hanger shims 2 Screws M4x25 mm and 2 nuts M4 1 Service cable

00299016

00224182

Service cable

00224412

Pin connector

00088913

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HG and HR Moisture Analyzers

Chapter Overview

11 - Service Aids

RS9 RS9 connection cable for balance PC, 1m m/f

11101051

LC RS9 connection cable for LocalCan to RS9 connection

00229065

Detector cable, 8 strand

00225635

Coil cable, 4 strand

00224414

Connection board for weighing cells


B A D C E F G H I

00225306

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HG and HR Moisture Analyzers

Chapter Overview

12 - SOPs

12

SOPs
List of contents
12.1 12.2 Preventive Maintenance - Instructions . . . . . . . . 12-2 Preventive Maintenance - Report. . . . . . . . . . . . 12-10

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12-1

12.1

Preventive Maintenance - Instructions

Preventive Maintenance p. 1 of 8

SOP/Work Instruction:

Preventive Maintenance for halogen and infrared Moisture Analyzers


Content: 1. 2. 3. 4. 5. 6. 7. 8. Purpose Scope General Considerations PM Procedures Completion of work Typical duration Tools and References Annex

1. Purpose
This work instruction describes the procedures of Preventive Maintenance (PM) for halogen and infrared Moisture Analyzers. In order to establish an unified service as well as meeting our quality standards all METTLER TOLEDO trained and certified service technicians must follow this instructions. Depending on the country specific situation additional work steps may be performed, e.g. for Calibration Certificates or approved models.

2. Scope
Maintenance work is usually part of a METTLER TOLEDO Service contract. This SOP is the framework for PM and has to be followed. Only factory trained and METTLER TOLEDO certified technicians are allowed to execute preventive maintenance. All Moisture Analyzers of the families HR, HG, HB, as well as MJ are covered by this Work Instruction.

Document: 11793049 Page: 1/8


2005 Mettler-Toledo GmbH, Greifensee

Version: SOP21Dec2005 Substitutes: SOP29Sep2005

Date released: 21Dec2006/TH Date approved: 21Dec2006/TH

Preventive Maintenance p. 2 of 7

3. General Considerations
3.1 Recommended Service Intervals The Service Interval is defined by the customer depending on: - the importance of the Moisture Analyzers in the QA process - importance of the results delivered by the Moisture Analyzers - risk and liability of results - use of Moisture Analyzer (quantitative) - environment (dust, chemicals, etc.) Recommendation Depending on the accuracy required for the application and depending on the risk of the process, in case of inaccurate measurements or a malfunction of the Moisture Analyzers, we recommend the following maintenance intervals:
Risk: liability, life support Cost: loss, damage Preventive Maintenance Interval Absent-Normal Low-Medium Once a year Severe High Twice a year

3.2. Administrative Before starting work it is recommended to: - talk to the responsible person and explain the work to be done - Verify requirements with supervisor, e.g. approval for cleaning, adjustments, etc. ask responsible person for any other requirements - Get familiar with inter-company safety requirements

3.3. Calibration tests These tests are an extensive diagnosis of the instruments about its functioning and measurement properties. Typically, these tests are performed by an authorized and trained METTLER TOLEDO service technician and aim at the evaluation of the individual properties of the Moisture analyzer, i.e. repeatability, eccentric load, linearity and sensitivity. The values obtained of these properties can then be compared with the manufacturers Moisture Analyzer specifications whether they are met. The Calibration Procedure is described in the Document Test and Measurements for Mettler-Toledo (Calibration SOP) Doc.No:11793000.

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2005 Mettler-Toledo GmbH, Greifensee

Version: SOP21Dec2005 Substitutes: SOP29Sep2005

Date released: 21Dec2006/TH Date approved: 21Dec2006/TH

Preventive Maintenance p. 3 of 7

4. Preventive Maintenance Procedures


In order to work efficiently and accurate minimizing errors document all findings the PM Report Preventive Maintenance Report for Moisture Analyzers Doc. No: 11793050.

4.1 Identification Identify Moisture Analyzer and data regarding to service contract.

4.2 Customer Comments/Input Get comments and input of the users or supervisor working with the Moisture Analyzers.

4.3 Visual Inspection 4.3.1 Objective Find broken or worn parts which may prevent a proper operation.

4.3.2 Procedure and Acceptance Criteria Inspect - Housing - Keypad and display screen - Draft shield - Sample pan holder - Sample pan handler - Dryer unit - Halogen heating module - Leveling feet - AC adaptor and power cable Acceptance Criteria - No crack, dirt nor loose screws. - No crack and dirt. - Sits properly in the sample chamber - Sits properly in the bearing sleeve - Sits properly in the draft shield - Clear and no dirt, correct fit - Protecting class is not broken - Easy movable - No broken insulation and dirt

4.4 Cleaning 4.4.1 Objective Clean and check all components of the Moisture Analyzer

4.4.2 Procedure Do not use Nitro Solvents - Clean draft shield (if applicable) - Clean sample pan holder (if applicable) - Clean sample pan handler - Clean housing parts and display screen

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2005 Mettler-Toledo GmbH, Greifensee

Version: SOP21Dec2005 Substitutes: SOP29Sep2005

Date released: 21Dec2006/TH Date approved: 21Dec2006/TH

Preventive Maintenance p. 4 of 7

4.4.3 Acceptance Criteria All components of the Moisture Analyzers are free of debris and dust that would prevent normal function of the drying system.

4.5 Internal Inspection (if necessary) 4.5.1 Objective An internal inspection is advised if any of the following circumstances are found dirty and dusty environment unstable weighing behavior of the Moisture Analyzer

4.5.2 Procedure and Acceptance Criteria Any handling on electronic boards or components requires the use of appropriate ESD precautions, e.g. ESD mats and bracelets. Disconnect Power Inspect - Check if dirt is present at any place - Check boards, cables and cell - Check motors belts and rails Acceptance Criteria - Clean - No connectors unplugged, no visible damage on the cell - No dirt

4.6 Battery Check 4.6.1 Objective Assure seamless operation of the Moisture Analyzer without loosing stored time or date information.

4.6.2 Check Battery / Accumulator The lifetime of the internal Lithium battery can be expected to be greater or equal 5 years. In case the Moisture Analyzer is 5 years or older and the battery has not been changed, or the battery is in place for equal or more than 5 years, replace it with same type (HR/HG accumulator and HB/HL/MJ battery) (see SMA). All user settings, date and time get lost if battery is discharged.

4.6.3 Acceptance Criteria Either product is younger than 5 years or documented evidence shows that battery has been changed.

Document: 11793049 Page: 4/8


2005 Mettler-Toledo GmbH, Greifensee

Version: SOP21Dec2005 Substitutes: SOP29Sep2005

Date released: 21Dec2006/TH Date approved: 21Dec2006/TH

Preventive Maintenance p. 5 of 7

4.7 Calibration / Adjustments (if necessary) 4.7.1 Objective If the Moisture Analyzer is out of specification, either customers requirements or manufactures tolerances it needs to be adjusted to meet those specifications.

4.7.2 Procedure An adjustment is necessary if one of the calibration parameters is out of specification - Eccentricity - Linearity - Sensitivity - Temperature Do appropriate adjustments with regard to the Service Manual (SMA).

4.7.3 Acceptance Criteria All values are within the defined specifications

4.8 Final Test 4.8.1 Objective Assure proper operation and settings of the Moisture Analyzer. All peripherals are connected and working.

4.8.2 Procedure and Acceptance Criteria


Check - Leveling feet and level indicator - Connect dryer to mains (if applicable) - Check keypad - Check sample chamber (if applicable) - Check eccentricity - Check linearity - Check repeatability - Check function of peripherals (if applicable, e.g. printer or barcode reader) - Sample chamber in / out Acceptance Criteria - Level bubble is in center - No cable is bent - All keys are responding - Moves out and in smoothly - according to SMA - according to SMA - according to SMA - Working accordingly - according to SMA

4.9 Calibration Documents (if applicable) Depending on customers requirements issue all necessary calibration reports. Sign documents and get customers approval (sign-off)

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2005 Mettler-Toledo GmbH, Greifensee

Version: SOP21Dec2005 Substitutes: SOP29Sep2005

Date released: 21Dec2006/TH Date approved: 21Dec2006/TH

Preventive Maintenance p. 6 of 7

5. Completion of work
Affix all necessary labels and Service Sticker Inform supervisor of any deviations or non-conformances. Get Sign-off on all required documents. Hand over all necessary documents.

6. Typical Duration
These values for the duration are typical values under good conditions. Time may vary depending on various issues.

Typical duration incl. Balance type incl. temperature test (min) HR ............................................. 60 HB ............................................. 45 MJ / HL ...................................... 45

Excluded in this estimation are: x any repairs x issuing additional national Calibration Certificates x acclimatizing weights and Moisture Analyzer x heavy cleaning x check of complex peripherals other than e.g. printer or barcode reader x without temperature adjustment

7. Tools and References


1. Test and Measurement Methods for Mettler-Toledo analytical and precision balances (11793000) 2. Preventive Maintenance Report for Moisture Analyzers Doc. No: 11793050. 3. Service Manual for Moisture Analyzers.

Document: 11793049 Page: 6/8


2005 Mettler-Toledo GmbH, Greifensee

Version: SOP21Dec2005 Substitutes: SOP29Sep2005

Date released: 21Dec2006/TH Date approved: 21Dec2006/TH

Preventive Maintenance p. 7 of 7

8. Annex
Annex A - Preventive Maintenance Flowchart

Start PM

Visual Inspection

Depending on Service Contract type


Fail Acceptance Document on PM report Repair or exchange

Pass

Cleaning

No

Internal Inspection Required ? Yes

Internal Inspection

Fail Acceptance Document on PM report Repair or exchange

Pass

Calibration SOP

Calibration/ Adjustments

Final Test

Fail Acceptance Pass Document on PM report Repair or exchange

Complete Documents

Review with Customer

End PM

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2005 Mettler-Toledo GmbH, Greifensee

Version: SOP21Dec2005 Substitutes: SOP29Sep2005

Date released: 21Dec2006/TH Date approved: 21Dec2006/TH

Annex B - Change History Version Changes SOP21Dec2006 - first edition

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2005 Mettler-Toledo GmbH, Greifensee

Version: SOP21Dec2005 Substitutes: SOP29Sep2005

Date released: 21Dec2006/TH Date approved: 21Dec2006/TH

12.2

Preventive Maintenance - Report

Preventive Maintenance Report for halogen and infrared Moisture Analyzers

1. Basic Information
Company______________ Address____________________________________________ Contact _______________ Unit Location__________ Product _______________ S/N _________________ Tel. ________________________ Remarks____________________

Customer comments

2. Visual inspection
Inspect Acceptance Criteria Fulfilled
Passed Failed

Comments
n/a

- Housing - Keypad and display screen - Draft shield - Sample pan holder - Sample pan handler - Dryer unit - Halogen heating module - Leveling feet - AC adaptor and power cable

- No crack, dirt nor loose screws. - No crack and dirt. - Sits properly in the sample chamber - Sits properly in the bearing sleeve - Sits properly in the draft shield - Clear and no dirt, correct fit - Protecting class is not broken - Easy movable - No broken insulation and dirt

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2005 Mettler-Toledo AG, Greifensee

Version: CL21Dec2005 Substitutes: CL29Sep2005

Date released: 21Dec2005/TH Date approved: 21Dec2005/TH

3. Internal inspecion
Inspect Acceptance Criteria Fulfilled
Passed Failed

Comments
n/a

- Check if dirt is present place - Check boards, cables and cell - Check motors belts and rails

- Clean - no visible damage on the cell - No dirt

4. Final test
Inspect Acceptance Criteria Fulfilled
Passed Failed

Comments
n/a

- Leveling feet and level indicator - Connect dryer to mains - Check keypad - Check sample chamber - Check eccentricity - Check linearity - Check repeatability - Check function of peripherals - Sample chamber in / out

- Level bubble is in center - No cable is bent - All keys are responding - Moves out and in smoothly - according to SMA - according to SMA - according to SMA - Working accordingly - according to SMA

5. Completion
Performed by: _____________________
(Name)

Date:_______

Signature: ___________________

Customer :

_____________________
(Name)

Date:_______ Signature:____________________

6. Next Preventive Maintenance


Due Date:__________________

7. References
All work is based on the SOP Preventive Maintenance for halogen and infrared Moisture Analysers Doc.No: 11793049

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2005 Mettler-Toledo AG, Greifensee

Version: CL21Dec2005 Substitutes: CL29Sep2005

Date released: 21Dec2005/TH Date approved: 21Dec2005/TH

HG and HR Moisture Analyzers

Chapter Overview

Index

Index
A
Adobe Acrobat Reader Navigation 1-3 Navigation on screen 1-3 Auxiliary Displays 2-1

O
Overview of HG/HR Moisture Analyzers 1-6

P
Preventive Maintenance Instructions 12-2 Report 12-10

B
Battery replacing of 6-25 Bearings replacing of 6-41, 6-41

S
Serial Number Decoding 1-5 Service Aids and Tools 11-1

C
CPU PCB Reset 6-24

T
Tolerances Drawer in/out 9-3 Eccentricity 9-2 Level adjustment 9-3 Linearity 9-2 Repeatability 9-2 Sensitivity 9-2 Temperature 9-3

D
Disposal of service materials
2-2

L
LARS Latest version 7-2 latest version 7-3 Operating instructions 7-2 What is LARS? 7-2

W
Weighing Cell Adjustments 6-44 Replacement 6-36
Mettler-Toledo AG I-1

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