321-78209 Jan. 2016 Electronic Balance Ionizer STABLO-AP Service Manual Analytical & Measuring Instruments Division
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Table of Contents 1. Precautions for Troubleshooting... 1 1.1 Preliminary Check... 1 1.2 Visual Check... 1 1.3 Handling Precautions... 1 2. Troubleshooting... 2 2.1 The [POWER] indicator does not illuminate.... 2 2.2 The [ALARM] indicator illuminates.... 3 2.3 The key switch does not function.... 4 2.4 Other function.... 5 3. Replacing Parts... 6 3.1 Disassembling the Case... 6 3.2 Assembling the Case... 7 3.3 Removing and Replacing Circuit Boards... 10 3.4 Replacing Electrode Probes... 13 4. Checking Functionality... 14 5. Maintenance Parts... 15
1. Precautions for Troubleshooting 1.1 Preliminary Check Before troubleshooting, check the following. (1) Is the AC power cord disconnected or damaged? (2) Is the AC adapter connected properly? 1.2 Visual Check Open the ionizer cover and visually check for any problems, such as broken cable connections or cut or short-circuited circuit board wiring patterns. 1.3 Handling Precautions Disconnect the AC adapter before opening the ionizer cover. Be careful to prevent injury when handling the electrode probe, which has a very sharp point.
2. Troubleshooting 2.1 The [POWER] indicator does not illuminate. [POWER] indicator is not illuminated Is the AC adapter fully inserted? Insert the AC adapter plug all the way in. Turn the power switch ON and OFF several times. Finished Use an electrical tester to verify that the adapter output is normal. (24 V) Is the adapter functioning normally? Replace the adapter with one that functions properly. Check the LED board connections (connector insertion and solder joints). Finished Replace all circuit boards. Replace individual circuit boards in the following sequence. (1) LED board (2) Interface board (3) Power board (4) CPU board Adjust the ion balance if the LED board was replaced. Note: Adjust the trimmer to the same angle. The transformer is damaged. It must be repaired. Finished
2.2 The [ALARM] indicator illuminates. The [ALARM] indicator is illuminated. Is there debris or other contaminant near the electrode probes? Unplug the AC adapter and remove the debris or other contaminant. Turn the power switch ON and OFF several times. Finished Check for contact with the opposing electrode (connector insertion or solder joint) Finished Replace all circuit boards. Replace individual circuit boards in the following sequence. (1) LED board (2) Interface board (3) Power board (4) CPU board Adjust the ion balance if the LED board was replaced. Note: Adjust the trimmer to the same angle. The transformer is damaged. It must be repaired. Finished
2.3 The key switch does not function. The key switch does not Is there key stroke movement? Remove the upper cover. Remove the upper cover. Is there a clicking sensation when the button on the circuit board is pressed? Fit the button properly into the boss in the upper cover. Note: It only fits properly in the specified orientation. Is the LED connector fully inserted? Replace the power board. Fully insert the LED connector. Replace the LED board. Finished Finished Adjust the ion balance if the LED board was replaced. Note: Adjust the trimmer to the same angle. Finished
2.4 Other function.
3. Replacing Parts 3.1 Disassembling the Case 1) Remove three screws from the back of the ionizer case. Use a #0 Phillips screwdriver to unscrew the screw circled in yellow (20 mm long tapping screw with 2.6 mm nominal diameter) and a #1 Phillips screwdriver to unscrew the two screws circled in blue (16 mm long tapping screw with 3 mm nominal diameter). 2) Remove the upper cover. Note: There are tabs located near the area circled in red. Remove the upper cover carefully, being especially careful of the tabs. 3) Remove the LED board. Remove the board by gripping the top of the board and pulling it away from the cover, in the direction shown. 4) Place the ionizer on a flat surface and remove the one screw that fastens the circuit board assembly. Use a #0 Phillips screwdriver to remove the screw circled in red (6 mm long tapping screw with 3 mm nominal diameter).
5) Remove both the circuit boards and base together from the lower cover. Note 1: Remove both the circuit boards and base from the lower cover together at the same time. Note 2: They can be removed more easily by turning them upside down. Note 3: The thin metal electrode plate may be disconnected from the base. Be careful not to bend it. Also be careful not to cut your hand on its sharp edges. Note 4: Be careful not to poke or scratch yourself on the sharp metal needleshaped electrode probes that are installed on the base. 3.2 Assembling the Case 1) Temporarily secure the button. Note: Insert the button into the designated hole in the upper cover in the orientation that allows it to fit smoothly. Then temporarily secure it from the outside of the cover using masking tape or other means. 2) Insert the circuit boards and base into the lower cover. Note: Make sure that four base alignment bosses are fitted into the corresponding slots in the lower cover and the circuit board is fitted into its alignment slot.
3) Make sure the cable is not pinched in the lower cover. Note: Confirm that the cable is not next to the boss circled in red. If it is, use tweezers or other tool to move it away from the boss. 4) Screw the circuit board to the lower cover. Use a #0 Phillips screwdriver to fasten the screw circled in red (6 mm long tapping screw with 3 mm nominal diameter). 5) Install the LED board into the upper cover. Note: Press the edge of the LED board against the LED board mounting area on the upper cover. Then, with the edge pressed against the edge of the mounting surface, tilt the LED board and press into position.
6) Install the upper cover onto the lower cover. Note 1: Be careful of the cable routing from the LED board. Make sure the cable passes through the notch (circled in red) in the base. Note 2: Insert the upper cover by engaging the tabs, visually inspecting to make sure the cable is not pinched and there is no gap between the covers. 7) Fasten the three screws into the back of the ionizer case. Use a #0 Phillips screwdriver to fasten the screw circled in yellow (20 mm long tapping screw with 2.6 mm nominal diameter) and a #1 Phillips screwdriver to fasten the two screws circled in blue (16 mm long tapping screw with 3 mm nominal diameter). Remove the masking tape from the upper cover button and check if the button operates correctly. (It should have a clicking sensation.)
3.3 Removing and Replacing Circuit Boards 1) Remove the circuit boards and base from the lower cover, as described in 3.1. 2) First remove the interface board from the other boards, being careful not to damage the connector that connects the boards. Interface board 3) Then remove the power board by loosening one screw and carefully disconnecting the connector between the boards. Power board
Note: The discharge electrode plate and electrode probes are connected to the power board via a cable and connector. 4) Disconnect the LED board from the CPU board. The LED board is connected to the CPU board via a cable and connector. CPU board LED board 5) Replace the board that needs to be replaced and reassemble the boards by reversing the steps above. 6) Install the circuit boards and base into the lower cover, as described in 3.2. Note: Precautions for Replacing Circuit Boards To reduce the number of adjustment labor hours, method A is recommended for replacing circuit boards. A. Not Replacing the LED Board 1. Use the maintenance part (321-73724) to replace everything except the new LED board (dispose of the new LED board). B. Replacing the LED Board. 1. Remove the old LED board from the main STABLO unit and other circuit boards. 2. Measure the resistance values between H501 and H502 on the old LED board. (Record the result as value A. Measure up to XX kω, or 4.51 kω, for example.) 3. Measure the resistance values between H502 and H506 on the old LED board. (Record the result as value B, measuring up to XX kω or about 10.00 kω.) 4. Measure the resistance values between H502 and H506 on the new board. (Record the result as value C, measuring up to XX kω or 10.50 kω, for example.)
5. Adjust the trimmer value on the new board to the value determined by the calculation A/B C. Measure and adjust the resistance between H501 and H502 (to within an adjustment error of ±0.04 kω). (In this example, adjust the resistance to A/B C = 4.51/10.00 10.50 = 4.74 kω.) H501 H502 H506 トリマ
3.4 Replacing Electrode Probes 1) Remove the circuit boards and base from the lower cover, as described in 3.1. 2) Pull out the electrode probe from the base. Note 1: Pull out the electrode probe by gripping it with needle nose pliers at the base of the probe. Note 2: Be careful of the sharp point on electrode probes. 3) Insert a new electrode probe. Note 1: Insert the electrode probe into the socket by gripping it with needle nose pliers on main shaft section of the probe. Note 2: When gripping an electrode probe with needle nose pliers or other tool, be sure to grip it along the shaft section of the probe. Gripping it on the tapered section could chip the electrode probe. Note 3: Insert electrode probes securely all the way in. 4) Check the tip of the inserted electrode probe. Note 1: Check the following two points. Check the electrode probe tip area for chips or bending. Confirm that the electrode probe tip is not excessively protruding or recessed. Note 2: If there is a problem with an electrode probe, replace it with a new one (only the probe with a problem). 5) Install the circuit boards and base into the lower cover, as described in 3.2.
4. Checking Functionality Confirm that the product functions properly after replacing a part. 1) Connect the ionizer to the power supply and confirm that the LED indicator illuminates. (If it does not illuminate, see 2. Troubleshooting and take necessary measures.) 2-1) Rub a sheet of fluoropolymer and nylon together and then use a quick static checker (P/N 321-73033) to confirm that the static charge at a perpendicular distance of 30 mm from the fluoropolymer sheet is about -5 kv. If inadequate, rub the sheets together again. (Static charge does not develop as readily if both sheet surfaces are not clean. In that case, resolve the problem by cleaning both sheet surfaces with alcohol.) 2-2) Then operate the ionizer unit for five seconds at a perpendicular distance of 30 mm from the fluoropolymer sheet, moving the ionizer as though it was spraying the entire sheet surface with mist. The purpose of moving the ionizer is to remove the static charge uniformly from the entire fluoropolymer sheet. 2-3) Then use the quick static checker (P/N 321-73033) again to confirm that the static charge at a perpendicular distance of 30 mm from the fluoropolymer sheet is about -300 V. 2-4) If the value is inappropriate, repeat the test. Then if there is a problem, see 2. Troubleshooting.)
5. Maintenance Parts No. P/N Description Remarks 1 321-73711 Brush BRUSH 2 321-73714 Dedicated AC Adapter AC ADAPTER,ATS024-P240 3 321-73723 Electrode Probe ELECTRODE PROBE Sold individually (seven probes used) 4 321-73724 Circuit board unit CIRCUIT BOARD UNIT 5 321-74069 Jig, PTFE JIG, PTFE 6 321-74070 Jig, NYLON JIG, NYLON 7 321-73033 Static-E tester STATIC-E TESTER 8 321-72984-41 Cable assy, ionizer CABLE ASSY, IONIZER 9 321-62523-01 Caution label CAUTION LABEL