OHAUS TROOPER Service Manual
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OHAUS TROOPER Service Manual

OHAUS TROOPER Service Manual

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®
TROOPER
®
TROOPER
SERVICE MANUAL
Ohaus Corporation 19A Chapin Road, P.O. Box 2033, Pine Brook, NJ 07058 (973) 377-9000
SCALE &
COUNT SCALE

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  • Page 1 ® TROOPER SCALE & ® TROOPER COUNT SCALE SERVICE MANUAL Ohaus Corporation 19A Chapin Road, P.O. Box 2033, Pine Brook, NJ 07058 (973) 377-9000...
  • Page 3 ® The information contained in this manual is believed to be accurate at the time of publication, but Ohaus Corporation assumes no liability arising from the use or misuse of this material. Reproduction of this material is strictly prohibited. Material in this manual is subject to change.

  • Page 5: Table Of Contents

    Replacing the Trooper Scale Load Cell Assembly ............. 3-4 Replacing the Trooper Count Scale Membrane Switch ..........3-6 Replacing the Trooper Count Scale Main PC Board ..........3-7 Replacing the Trooper Count Scale Display PC Board ..........3-8 Replacing the Trooper Count Scale Load Cell Assembly..........3-9...
  • Page 6 Installation ...................... B-1 B.2.1 Minimum Requirements ................B-1 B.2.2 Connecting the RS232 Interface ..............B-1 B.2.3 Installing the Trooper Count Scale Tools Software Program ......B-1 B.2.4 Opening the Trooper Count Scale Tools Software Program ......B-1 Screen Operations ....................B-2 B.3.1 Configuration (Config) ................
  • Page 7 Trooper Scale - Cannot Calibrate............2-4 Trooper Scale - Communications Failure ..........2-6 Trooper Scale Error Codes ..............2-8 Trooper Count Scale - Will Not Turn on With AC Adapter ......2-9 Trooper Count Scale - Will Not Turn on Using Batteries ......2-10 2-10 Trooper Count Scale - Does Not Respond to Front Panel Controls ....
  • Page 8 LIST OF ILLUSTRATIONS (Cont.) FIGURE NO. TITLE PAGE Sample Calculation of Standard Deviation ..........4-4 Off-Center Load Test Weight Locations ..........4-4 RS232 Interface Pin Connections ............4-8 Expoded View of Trooper Scale and Trooper Count Scale......5-2...

  • Page 9: Chapter 1 Introduction

    Chapter 3 Repair Procedures - Contains detailed repair procedures for all major components. Chapter 4 Testing - Contains performance tests, specifications and communications testing procedures. Chapter 5 Parts Lists - Contains exploded views of Trooper Scale and Trooper Count Scale identifying all serviceable replacement components with associated parts lists.

  • Page 10: Tools And Equipment

    CALIBRATION MASSES REQUIRED The masses required to test the Ohaus Trooper Scale and Trooper Count Scale must meet the requirements of ASTM Class 4 or OIML F2. The mass values are listed in Table 1-1. Bolded values are default settings.

  • Page 11: Service Strategy

    CHAPTER 1 INTRODUCTION 1.4 SERVICE STRATEGY The repair method for the Trooper Scale and Trooper Count Scale is the direct substitution of major assemblies. The Trooper Scale contains 3 major replaceable assemblies: Cover Assembly with Membrane Switch, Load Cell Assembly with Frame and the Main PC Board with LCD.
  • Page 12 CHAPTER 1 INTRODUCTION...

  • Page 13: Chapter 2 Diagnosis

    Trooper Count Scales are covered in Tables 2-8 through 2-14. The troubleshooting tables refer to interconnection and wiring diagrams in this section to assist in locating the problem. TABLE 2-1 TROOPER SCALE - WILL NOT TURN ON WITH AC ADAPTER. REMEDY SYMPTOM PROBABLE CAUSE Check the ac adapter voltage output.

  • Page 14: Trooper Scale - Will Not Turn On Using Batteries

    CHAPTER 2 DIAGNOSIS TABLE 2-2 TROOPER SCALE - WILL NOT TURN ON USING BATTERIES. PROBABLE CAUSE REMEDY SYMPTOM Check position of batteries. Incorrect battery installation. Scale will not turn on with new batteries installed. Remove the 6 screws from the bottom...

  • Page 15: Trooper Scale - Does Not Respond To Front Panel Controls

    CHAPTER 2 DIAGNOSIS TABLE 2-3 TROOPER SCALE - DOES NOT RESPOND TO FRONT PANEL CONTROLS. PROBABLE CAUSE SYMPTOM REMEDY 1. Open the scale, remove six screws Membrane Switch is defec- Scale does not respond to front from the bottom of the scale.

  • Page 16: Trooper Scale - No Display Or Partial Display

    CHAPTER 2 DIAGNOSIS TABLE 2-4 TROOPER SCALE - NO DISPLAY OR PARTIAL DISPLAY. PROBABLE CAUSE REMEDY SYMPTOM The Main PC Board is replaced as a Main PC Board is defective. Display is not on or partial whole assembly. Check procedures in characters are displayed.
  • Page 17 CHAPTER 2 DIAGNOSIS TABLE 2-5 TROOPER SCALE - CANNOT CALIBRATE (Cont.). SYMPTOM PROBABLE CAUSE REMEDY Scale can be turned on but will Load Cell assembly defec- With the platform in place and the scale not calibrate (Cont.). tive. turned on, measure across pins -SIG and +SIG on the PC Board.

  • Page 18: Trooper Scale - Communications Failure

    CHAPTER 2 DIAGNOSIS TABLE 2-6 TROOPER SCALE - COMMUNICATIONS FAILURE. SYMPTOM PROBABLE CAUSE REMEDY Communications cannot be Communication cable is not Tighten connectors and use the proper established with scale turned plugged in or the incorrect cable. cable is being used.

  • Page 19: Trooper Scale Diagrams

    Main PC Board Black TARE ON/ZERO & OFF Battery Holder G/N/T & MENU PRINT UNITS COMM Black NOT USED Figure 2-1. Trooper Scale Interconnection Diagram. Print G/N/T On/Zero Tare Units Menu MEMBRANE SWITCH Figure 2-2. Trooper Scale Membrane Switch Wiring Diagram.

  • Page 20: Trooper Scale Error Code Table

    CHAPTER 2 DIAGNOSIS 2.5 TROOPER SCALE ERROR CODE TABLE The Trooper Scale is equipped with software which will display an error condition when it occurs. Review the listed codes and follow instructions to correct the problem. TABLE 2-7. TROOPER SCALE ERROR CODES...

  • Page 21: Trooper Count Scale - Will Not Turn On With Ac Adapter

    CHAPTER 2 DIAGNOSIS TABLE 2-8 TROOPER COUNT SCALE - WILL NOT TURN ON WITH AC ADAPTER. SYMPTOM PROBABLE CAUSE REMEDY Scale will not turn on with AC Adapter defective. Check the ac adapter voltage output. adapter supplied. The ac adapter output should measure 12-16 Volts dc.

  • Page 22: Trooper Count Scale - Will Not Turn On Using Batteries

    CHAPTER 2 DIAGNOSIS TABLE 2-9 TROOPER COUNT SCALE - WILL NOT TURN ON USING BATTERIES. PROBABLE CAUSE REMEDY SYMPTOM Incorrect battery installation. Check position of batteries. Scale will not turn on with new batteries installed. Wiring harness defective or Remove the 6 screws from the bottom...

  • Page 23: Trooper Count Scale - Does Not Respond To Front Panel Controls

    CHAPTER 2 DIAGNOSIS TABLE 2-10 TROOPER COUNT SCALE - DOES NOT RESPOND TO FRONT PANEL CONTROLS. PROBABLE CAUSE SYMPTOM REMEDY 1. Open the scale, remove six screws Membrane switch defective. Scale does not respond to front from the bottom of the scale.

  • Page 24: Trooper Count Scale - No Display Or Partial Display

    CHAPTER 2 DIAGNOSIS TABLE 2-11 TROOPER COUNT SCALE - NO DISPLAY OR PARTIAL DISPLAY. SYMPTOM PROBABLE CAUSE REMEDY Display is not on or partial Either the display board con- Remove the 6 screws from the bottom characters are displayed. nector is loose from the Main...

  • Page 25: Trooper Count Scale - Cannot Calibrate

    CHAPTER 2 DIAGNOSIS TABLE 2-12 TROOPER COUNT SCALE - CANNOT CALIBRATE. PROBABLE CAUSE SYMPTOM REMEDY Incorrect weights. Verify that proper weights are used. Scale can be turned on but will not calibrate. The software lock menu is Set the software lock menu to OFF. Ac- set ON.(LOC CAL ON)

  • Page 26: Trooper Count Scale - Communications Failure

    CHAPTER 2 DIAGNOSIS TABLE 2-12 TROOPER COUNT SCALE - CANNOT CALIBRATE (Cont.). PROBABLE CAUSE REMEDY SYMPTOM Main PC Board is defective. If the above readings are within limits, Scale can be turned on but the Main PC Board is defective.

  • Page 27: Trooper Count Scale Diagram

    CHAPTER 2 DIAGNOSIS 2.6 TROOPER COUNT SCALE DIAGRAM 2-15...

  • Page 28: Trooper Count Scale Error Codes

    CHAPTER 2 DIAGNOSIS 2.7 TROOPER COUNT ERROR CODE TABLE TABLE 2-14. TROOPER COUNT SCALE ERROR CODES. ERROR CODE CAUSE REMEDY Batteries are weak. [Batt ][Low ][ Replace batteries. [Err 1][over][Load] The load on the platform ex- Remove excess load. Refer to the Trouble- ceeds the rated capacity of shooting Tables.
  • Page 29 CHAPTER 2 DIAGNOSIS TABLE 2-14. TROOPER COUNT SCALE ERROR CODES (Cont.). REMEDY CAUSE SYMPTOM Recalibrate scale. If the problem per- Capacity point parameter [CAP][data][Error] sists, replace the Main PC board or Load check failed during program Cell. running. Recalibrate the scale.
  • Page 30 CHAPTER 2 DIAGNOSIS ROW1 ROW1 ON/OFF ON/OFF ROW2 ROW2 ROW3 ROW3 ROW4 ROW4 COL1 COL1 COL2 COL2 COL3 COL3 COL4 COL4 COL5 COL5 Figure 2-4. Trooper Count Scale Membrane Switch Wiring Diagram. 2-18...

  • Page 31: Chapter 3 Repair Procedures

    CHAPTER 3 REPAIR PROCEDURES 3. REPAIR PROCEDURES This section describes how to change individual components of the Trooper Scale and Trooper Count Scale. When doing this, please refer to the exploded view drawings and parts lists in section 5. Important: After replacing components, a functional check of the scale must always be carried out.

  • Page 32: Replacing The Trooper Scale Main Pc Board

    CHAPTER 3 REPAIR PROCEDURES 3.2 REPLACING THE TROOPER SCALE MAIN PC BOARD The Main PC Board is located inside the scale towards the front. To replace the Main PC Board, it is necessary to disassemble the scale. 1. Perform steps 1 through 4 of paragraph 3.1.
  • Page 33 +SEN JUMP 1 Figure 3-2. Trooper Scale RS Connector and Loadcell Connector Wiring. 10.Check the LFT lock switch (legal for trade) switch (S1). Make sure it is in the ON position. 11.Turn on the scale. When self testing is completed, the display may indicate an error code. This is normal.

  • Page 34: Replacing The Trooper Scale Load Cell Assembly

    CHAPTER 3 REPAIR PROCEDURES 3.3 REPLACING THE TROOPER SCALE LOAD CELL ASSEMBLY The Load Cell Assembly is centrally located inside the scale. See Figure 3-3. The load cell is factory assembled and the down stops are preadjusted. There are no adjustments to be made on this assembly after installation.
  • Page 35 CHAPTER 3 REPAIR PROCEDURES 3.3 REPLACING THE TROOPER SCALE LOAD CELL ASSEMBLY (Cont.) DC POWER JACK BATTERY BOX RS232 CONNECTOR LOAD CELL ASSEMBLY FERRITE CORE LOAD CELL LFT LOCK SWITCH RS232 CABLE BATTERY BOX LOAD CELL & CABLE POWER CONNECTOR...

  • Page 36: Replacing The Trooper Count Scale Membrane Switch

    CHAPTER 3 REPAIR PROCEDURES 3.4 REPLACING THE TROOPER COUNT SCALE MEMBRANE SWITCH The membrane switch is affixed to the upper housing of the scale. The scale must be disassembled to gain access to the membrane switch connections. 1. Remove power from the scale.

  • Page 37: Replacing The Trooper Count Scale Main Pc Board

    3.5 REPLACING THE TROOPER COUNT SCALE MAIN PC BOARD NOTE: Do not attempt this procedure unless you have the Trooper Count Scale Tools program. The Main PC Board is located inside the scale towards the front. To replace the Main PC Board, it is necessary to disassemble the scale.
  • Page 38 10. After the scale is turned on, the display will show Error 21 => Cal => Data. 11. Refer to Appendix B and start Trooper Count Scale Tools. 12. Select the model of the Trooper Count Scale in the Model box. 13.Enter the serial number in the serial number box.

  • Page 39: Replacing The Trooper Count Scale Display Pc Board

    CHAPTER 3 REPAIR PROCEDURES 3.6 REPLACING THE TROOPER COUNT SCALE DISPLAY PC BOARD The Display PC Board is located on the inside of the upper housing. To replace the Display PC Board, it is necessary to disassemble the scale. 1. Perform steps 1 through 4 of paragraph 3.4.
  • Page 40 LFT LOCK SWITCH POWER CONNECTOR CABLES DISPLAY POWER & SIGNALCABLE LOAD CELL DISPLAY CABLE CONNECTOR J2 J3 RS232 CABLE LCD DISPLAY BOARD MEMBRANE SWITCH CONNECTORS MEMBRANE SWITCH CABLES SCALE BASE TOP COVER Figure 3-6. Trooper Count Scale Component Locations. 3-10...

  • Page 41: Chapter 4 Testing

    CHAPTER 4 TESTING 4. TESTING Before and after servicing the Trooper Scale and Trooper Count Scale, they should have an operational test and various performance tests made to ascertain whether or not the scale meets specifications. Turn the scale on and allow it warm up for at least one hour before performing these tests. Make sure the test area is free from drafts and the surface that the scale rests on is level and vibration free.

  • Page 42: Performance Tests

    Set the scale readability to the factory default setting. This can be done by means of the Setup Menu – Reset function for the Trooper Count Scale and setting the Trooper Scale to kg. A scale passing each of these three tests complies with Ohaus specifications.
  • Page 43 CHAPTER 4 TESTING 4.3.1 Repeatability Test (Cont.) σ Figure 4-3. Standard Deviation ( ) Worksheet. Reading Weight (kg) Weight - Mean (Weight – Mean) SUM = SUM = Mean = SUM/10 Variance = SUM/9 σ Mean = = = = = = Variance σ...

  • Page 44: Sample Calculation Of Standard Deviation

    CHAPTER 4 TESTING 4.3.1 Repeatability Test (Cont.) σ Figure 4-5. Sample Calculation of Standard Deviation ( ). Reading Weight (kg) Weight - Mean (Weight – Mean) 3000.0 -.02 .0004 3000.0 -.02 .0004 3000.2 .0324 3000.0 -.02 .0004 3000.2 .0324 3000.0 -.02 .0004 2999.8...

  • Page 45: Linearity Test

    7. Subtract the center position reading from the reading at each outer position. The difference at each test position should be within the cornerload tolerance specified in Table 4-1 for Trooper Scale and Table 4-2 for Trooper Count Scale. 4.3.3 Linearity Test The Linearity test is used to determine the linearity of the scale throughout its operating range.

  • Page 46: Trooper Scale Specifications

    480oz X 0.2oz 960oz X 0.5oz Linearity (g) +0.5g Repeatability +0.5g Off Center Load +0.5g 4.5 TROOPER COUNT SCALE SPECIFICATIONS TABLE 4-2. TROOPER COUNT SCALE SPECIFICATIONS. Model TC3RS TC6RS TC15RS TC30RS Default Capacity X Readability (lb) 6lb X 0.001lb 15lb X 0.002lb 30lb X 0.005lb...

  • Page 47: Communication Test

    4.6.2 Setting Trooper Count Scale Print Menu The Trooper Count Scale also contains a print menu with the following submenus: Baud Rate, Data Length, Parity Bit, Print Part No., Print Count, Print APW, Print Net, Print Tare, Print Total PCS, Print Gross, print on Stable, Print Header and Print Style.

  • Page 48: Rs232 Interface Pin Connections

    RS232 Command Table 4-3 for Trooper Scale and Table 4-4 for Trooper Count Scale. See Figure 4-7 for connections. When the scale is connected directly to a printer, displayed data can be output at any time by simply pressing PRINT UNITS button on the Trooper Scale and Trooper Count Scale.

  • Page 49: Print Test

    4. Press PRINT Unit button, the computer or a printer should record the weight value. 5. Refer to Tables 4-3 for the Trooper Scale and 4-4 for the Trooper Count Scale and try all commands and verify operation of the scale.
  • Page 50 CHAPTER 4 TESTING 4-10...

  • Page 51: Chapter 5 Parts Lists

    CHAPTER 5 PARTS LISTS 5. PARTS LISTS This section of the manual contains exploded views, and parts lists for the Trooper Scale and Trooper Count Scale. The exploded view drawings identifies the replaceable parts. NOTE: In all cases where a part is replaced, the scale must be thoroughly checked after the replacement is made.

  • Page 52: Trooper Scale/Trooper Count Scale Exploded View

    CHAPTER 5 PARTS LISTS 5.1 Trooper Scale/Trooper Count Scale Exploded View 11 1 Figure 5-1. Exploded View of Trooper Scale and Trooper Count Scale.

  • Page 53: Trooper Scale (Tr) And Trooper Count Scale (Tc)Parts List

    CHAPTER 5 PARTS LISTS TABLE 5-1. TROOPER SCALE (TR) AND TROOPER COUNT SCALE (TC) PARTS LIST ITEM NO. PART NO. DESCRIPTION QUANTITY 71133849 Platform Assembly, TR, TC 71133037 Membrane Switch, TR 71138748 Membrane Switch, TC 71102326 Level, TR, TC 71133160...
  • Page 54 CHAPTER 5 PARTS LISTS TABLE 5-1. TROOPER SCALE (TR) AND TROOPER COUNT SCALE (TC) PARTS LIST (Cont.) ITEM NO. PART NO. DESCRIPTION QUANTITY 71132592 Display, LCD, TR 71138664 Display PC Board Assembly, TC 71115243 Spacer, Rubber, TR, TC 71116785 Display, LCD, TC...

  • Page 55: Appendix A Calibration

    The sample illustration indicates a 4kg mid point for a 6kg scale. (Linearity calibration for Trooper is 0, 2/3 and full capacity). Place the indicated mass on the platform. Keep the platform stable during this period.

  • Page 56: Trooper Count Scale Linearity Calibration

    APPENDIX A - CALIBRATION A.2 TROOPER COUNT SCALE LINEARITY CALIBRATION WEIGHT DATA COUNT The following example is with a 6kg Scale. With the Scale ON, press and hold the SAMPLE Menu button until CAL MENU is displayed. < > PT APW MR...
  • Page 57 APPENDIX A - CALIBRATION A.2 TROOPER COUNT SCALE LINEARITY CALIBRATION (Cont.) COUNT COUNT WEIGHT DATA COUNT < > < > < > B/G %Ac PT APW MR Place the indicated calibration mass on the pan. Press the Enter button. The sample illustration indicates a 6kg Scale using a 6kg mass.

  • Page 58: Linearity Calibration Weights

    APPENDIX A - CALIBRATION A.3 LINEARITY CALIBRATION WEIGHTS Linearity calibration weights are defined in Tables A1 and A-2 for the Trooper Scale and Trooper Count Scale. TABLE A-1 TROOPER SCALE LINEARITY WEIGHTS Cal in kg: Linearity cal (fixed) Masses Totaling TR3RS 2 &...

  • Page 59: Appendix B Trooper Count Scale Tools

    Scale. Through the RS232 interface, this program allows a user to configure the scale settings and library data and test output commands from a PC. Use of the Trooper Count Scale Tools is required after the main PC board of the Trooper Count Scale is replaced.

  • Page 60: Screen Operations

    Serial No. Serial No. • Serial No. Serial No. Serial No. Up to a 6-digit serial number of the Trooper Count Scale is entered in this field. Metric Unit Setting Metric Unit Setting • Metric Unit Setting Metric Unit Setting...
  • Page 61 • [Read Config Data from Scale] Button [Read Config Data from Scale] Button [Read Config Data from Scale] Button Select this button to load and display the configuration data from the scale into the Trooper Count Scale Tools program. [Write Config Data to Scale] Button [Write Config Data to Scale] Button •...

  • Page 62: Library

    APPENDIX B - TROOPER COUNT SCALE TOOLS B.3.2 Library The Library Screen offers a method to quickly and conveniently read, enter, and save individual Library records. The Library screen displays up to 60 part-files, each line representing a record that contains unique part- file information.
  • Page 63 APPENDIX B - TROOPER COUNT SCALE TOOLS U n i t U n i t • U n i t U n i t U n i t The selected unit of measurement. Select by scrolling through the available units: kg, lb, g or Note: Any changes to the record data will not be saved or take effect for scale operation until transferred into the scale or a file.
  • Page 64 Select this button to read (extract) all Library data from a file created from the [Write to File] Button in the Trooper Count Scale Tools program (refer following section). Specify the source directory, folder and file name as prompted on the following “Open” screen. Then select [Open] to execute the process.

  • Page 65: Test Command

    The scale will also reflect that the operation was executed. • V (Get Version Number) V (Get Version Number) V (Get Version Number) V (Get Version Number) V (Get Version Number) Displays the model and software version of the Trooper Count Scale on the “Response from scale” field.

  • Page 66: Com Port

    APPENDIX B - TROOPER COUNT SCALE TOOLS B.3.4 COM PORT The COM Port Screen allows the user to automatically set up RS232 connections, or manually specify scale print settings to establish proper communications. Automatic Setup is the default setting. The following scale Print Menu settings can be specified when...

  • Page 67: Troubleshooting

    Library Screen) when attempting to read a file that was not created from the [Write to File] Button in the Trooper Count Tools program. Open a file created from the [Write to File] Button. • Library error: Part number entry...
  • Page 68 APPENDIX B - TROOPER COUNT SCALE TOOLS B-10...
  • Page 70 Ohaus Corporation 19A Chapin Road, P.O. Box 2033 Pine Brook, NJ 07058, USA Tel: (973) 377-9000, Fax: (973) 593-0359 www.ohaus.com With offices worldwide. www.ohaus.com *80250952* P/N 80250952 Printed in USA © Ohaus Corporation 2004, all rights reserved.

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