DL37 SM e 710142

METTLER TOLEDO
Analytical Business location Schwerzenbach: Sonnenbergstrasse 74 (Industrie Vieri), 8603 Schwerzenbach, Switzerland 01-806 77 11 01-806 73 50
Address Phone Fax
Service Manual METTLER TOLEDO KF-Coulometer DL37

Current status of the service manual, see section E
Bild
*P704726*
Mettler-Toledo GmbH 1992, 1998 ME-704726A Printed in Switzerland 9806/8.12
Edition:
June 1998
General
Cautionary note Exploded view diagrams Spare parts list Service tools Instrument layout
Checking
Checklist maintenance Checklist service Service mode Function test
Troubleshooting
Fuses Test points Troubleshooting
Repairs
Corrective maintenance Calibration and checking the boards
Service bulletins
Supplements
Data section
Circuit and board component diagrams
DL37
General
Contents
1. 2. 2.1 2.1.1 2.1.2 2.1.3 2.1.4 3. 3.1 3.2 3.3 3.3 4. 5. 6. 6.1 6.2 6.2.1
Page
Cautionary notes ...................................................................................................... General information .................................................................................................. Technical changes ..................................................................................................... Software changes ...................................................................................................... Software changes overview ......................................................................................... Hardware changes ..................................................................................................... Software compatibility ................................................................................................ Exploded view diagrams ........................................................................................... Mechanical layout ...................................................................................................... Printer mechanism ..................................................................................................... Electrical layout ......................................................................................................... Cable connections .....................................................................................................
3 4 4 4 4 5 5 6 6 7 8 9
Spare parts list ......................................................................................................... 10 Service tools ............................................................................................................ 12 Instrument layout ...................................................................................................... 13 Mechanical layout ...................................................................................................... 13 Electrical layout ......................................................................................................... 15 Hardware description ................................................................................................. 15
Service Manual ME-704726A
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1.
Warning
Cautionary notes
When working with the titrator, please comply with the following basic rules ! Before the instrument is opened, the power plug must be disconnected from the power supply. The service engineer must be familiar with the Safety instructions for outsiders of the enduser company. Before corrective maintenance work is performed, the titration cell must be removed from the METTLER TOLEDO KF-Coulometer. Only those parts or assemblies specified in the spare parts list may be replaced. Karl Fischer reagents are toxic and may be disposed of only as specified by the regulations.
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2.
2.1
General information
Technical changes
Starting January 1996 (or starting with serial number MEB75C10) the DL37 that were delivered have some major changes in hard- and software. There are two reasons for these updates: - A few Software features of the DL37 have been changed to comply to GLP regulations. This new Software is Version 3.1AA. This new software can be used in older instruments as well by replacing the CPU4 board, which now has Software Version 3.1AA installed. - In order to pass the CE tests, changes in Hardware of DL37 had to be done, whereby older instruments cannot be updated.
2.1.1 Software changes

An external printer with RS interface can be connected to the DL37 in order to have protocols on a non thermo printer GLP conform print outs. For this, the optional RS interface (ME-105096) has to be installed. You have to configure the DL37 Function 6, choose printer and set the correct RS settings corresponding to the external printer. To connect the Printer GA42, the cable ME-51328094 is needed and the dip switch 2 has to be set to position on. The RS setting in Function 6 has to be 1200 baud / parity: no / stop bit: 2. Please note, that no graphics can be printed out on the GA42. It is however possible to connect a GA42 and print out on the DL37 internal printer at the same time, in order to have both GLP print outs and graphics. If only the internal printer is used and the balance/printer interface is installed, the Function 6 must be set to computer.
2.1.2 Software changes overview

- The print outs are now more complete, in order to be GLP conform. - An alpha-numerical user ID can be entered. - The ID# of the DL37 can be changed. - Re-calculation of a result.
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2.1.3 Hardware changes

In order to pass the CE tests, parts like CPU, Transformer and Power line filter had been changed or modified. The CPU Board is no longer a CPU 4 type, the new CPU has the designation CPU5. Furthermore the Olivetti printer has been replaced by a new one from Seiko. This printer does not have the paper lever on top of the printer housing. The missing printer lever with the new instruments makes it easy to distinguish CE and Non CE instruments. Many parts from old and new instruments cannot be mixed. In service cases, parts are always exchanged by the same type. For further information see also the spare parts list which now has two columns for Non-CE and CE instruments.
2.1.4 Software compatibility

ROM 1 CPU 4 1.7AA 1.9AA 3.1AA 3.1AA ROM 2 1.7AA 1.9AA 3.1AA 3.1AA ROM 3 1.7AA 1.7AA empty Empty Printer Olivetti Olivetti Olivetti Seiko CE no no no yes GLP no no yes yes
CPU 5
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3.
3.1
Exploded view diagrams

Mechanical layout
30
31 23
25
12
27
24
16
Vic tor Ma r hle
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3.2
Printer mechanism
13 29 28 22
13 29 28 22
33 6 10 5 6 5
10
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3.3
Electrical layout
14 11
7 32
9 4 3
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3.3
Cable connections
22 25
12
22 17 20 3
16 21
18 1
15 19
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4.
Spare parts list

Part number Non CE-Version 51106129 105022 51106130 105021 105024 105025 105026 105027 105028 105030 105031 105034 105041 105042 105152 105153 105154 105155 105156 105157 105158 105120 105121 105122 105159 18560 54286 Part number CE-Version 51106129 105022 51106130 105021 51106131 105025 105026 105027 51106133 51106134 105031 105034 51106137 51106135 105152 105153 105154 105155 105156 105157 105158 105120 105121 105122 105159 18560 51106155
Item Designation 1 Power line filter (New, backward compatible) 2 Power switch 3 Power socket (New, backward compatible) 4 NiCd battery 5 Thermal printer (Olivetti) Thermal printer (Seiko) 6 End-of-paper sensor 7 Preamplifier board 8 16-character display 9 CPU4 Processor board CPU5 Processor board 10 Printer connection board 11 Power supply board 12 Stirrer motor 13 Printer housing 14 Transformer 15 Connection cable, 50-pin (Preamplifier - CPU) 16 Connection cable, 14-pin (CPU - keypad) 17 Connection cable, 20-pin (CPU - printer) 18 Connection cable, 4-pin (Power board - CPU) 19 Connection cable, 3-pin (Preamplifier - CPU) 20 Connection cable, 2-pin(Preamplifier - stirrer) 21 Connection cable (CPU - DO337 socket) 22 Socket, 6-pin 23 Plug, 6-pin 24 Housing 25 Base for titration cell 26 Fuse 1.6 A, slow-blow (set of 3) (see page C3) 3.15 A, slow-blow (set of 3) 4 A, slow-blow (set of 5)
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Item Designation 27 Keypad 28 Socket 2 mm, red 29 Socket 2 mm, black 30 Plug 2 mm, red 31 Plug 2 mm, black 32 EMI board 33 EMI board
Part number Non CE-Version 105002 88549 88548 88554 88553 -
Part number CE-Version 105002 88549 88548 88554 88553 51106143 51106139
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5.
Service tools
The following special instruments are needed in addition to the normal tools: Socket wrench 5.5 mm for printing unit DVM, 3 1/2 digits resolution, impedance > 10 M Test cable 20 cm with clamps at both ends Frequency counter, oscilloscope 50 MHz Test instrument (Electrode simulator) ME-105127
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6.
6.1
Instrument layout
Mechanical layout
The mechanical layout of the METTLER DL37 KF Coulometer comprises the following units: - Titration cell with anode and cathode for the sample - Membrane keypad - Thermal printer for result output - Illuminated display - Interface for electronic balances for the input of sample data - Computer interface (RS-232C) for external acquisition of results and methods (see operating instructions of DL37 KF Coulometer) or for connecting an external printer.
Inner burette (integrated combination cathode/anode) Thermal printer
Drying tubes of titration cell
Detection electrode (double platinum pin electrode)
Titration cell Holder of titration cell
Illuminated display: Shows the number of the method, the background level, the status and the data Membrane keypad
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RS-232C
BALANCE
Power switch
Interface for electronic balance (option)
Computer interface (RS-232C) (option)
The greater part of the electronics of the DL37 KF Coulometer is in the bottom housing section: - Processor board - Preamplifier board - Rectifier board - Interface board - Toroidal-core transformer for power supply - Stirrer motor for magnetic stirrer All units are interconnected by plug-in connections and can be changed separately.
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6.2
Electrical layout
See exploded view diagrams Electrical layout and Cable connections (section A) and circuit diagrams (section F).
6.2.1 Hardware description

Power supply connection The power transformer is designed for the following input voltages: Line voltage 100 VAC 120 VAC 220 VAC 240 VAC Line frequency Primary circuit fusing Tolerance of the primary voltages Voltage range 90 to 121 V 103 to132 V 198 to 242 V 216 to 264 V 50/60 Hz fusible cutout 3.15 A slow-blow for 100 and 120 V fusible cutout 1.6 A slow-blow for 220 and 240 V 10 %
The following voltages are available in the secondary circuit: Voltage 38 V 16 V - 0 V - 16 V 16 V - 0 V - 16 V 24 V 8V Rectifier board The rectifier board is used to generate the direct voltages. The 24 VDC voltage stabilized by controller IC2 is supplied via connector CN-2.3 to the processor board ES-105136. It is used as a driver voltage for the non-CE thermal printer. For use in the DL37, the rectifier board is not fully populated. The 5 V processor voltage is generated by controller IC1 on the rectifier board. It is supplied to the processor board via connector CN-2.3. Thermal printer board This board is the connecting link between the processor board and the thermal printer. The thermal printer board incorporates the end-of-paper sensor. Function generator voltage 62 V IC amplifier supply Interface, IC amp 12 V printer supply 24 V (non-CE only) supply for logic 5 V Wiring color code yellow-yellow pink-white-pink / purple-white-purple blue-grey-blue orange-orange brown-brown
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Computer and balance interface Balance interface The interface for the balance is marked with balance (plug-in connection CN2). METTLER PE, PM, AE or AT balances with an RS-232C interface can be connected to the interface. The data format is defined using switches S0 -S5 or jumpers. Switch position: S0, S1, S2 = closed S3, S4, S5 = open
Computer interface The computer interface is marked with RS-232C (plug-in connection CN3). The hierarchy corresponds to DCE (Data Communication Equipment), but can be converted to DTE (Data Terminal Equipment) with a wired connection. The interface is configured with FUNCTION 6. The clock frequency for both interfaces is generated by the quartz crystal (F = 1.22 MHz). The interface voltage of 17 VAC is rectified on the interface board and stabilized to +12 V and 12 V with IC9 and IC10. Data interchange between the processor board and the interface takes place via plug-in connection CN1. Display board The display comprises - the 16-digit fluorescent display, - the driver circuits IC2 and IC6, - the demultiplexers IC3 and IC5, - character generator (IC1). The voltage of approx. 60 V needed for the lamp is generated in the DC/DC converter from the 5 V processor voltage. The CN2 plug-in connection is not used. Preamplifier board The measurement principle of the coulometric KF titration is based on the passage of a controlled constant current through special KF solutions. The relationship 2 x 96500 coulombs produce the amount of iodine required for reaction with 18 g water (10.71 coulombs/mg H2O) allows the detection and reliable measurement of even trace amounts of water. The stable measurement current needed for the iodine which reacts with water is produced by the fieldeffect transistor Q8, IC34 and the resistors R29 - R34. The current flows through the cathode, the catolyte and the perforated anode in the anolyte. The processes in the titration cell are detected with the double platinum pin electrode and led to the measuring amplifier via a stage separated galvanically by an optocoupler. A sinusoidal voltage (IC4/IC17, ROM IC16 and level converter IC28) serves as a reference variable. The titration is started by automatic control. The measurement begins 1 minute after the start ! At the start of measurement (high water content), the double platinum pin electrode carries an alternating voltage of
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approx. 600 mV. The end-level voltage with an anhydrous sample is approx. 200 mV. The voltages generated by the transformer and the power supply are rectified and stabilized on the preamplifier board. The voltage for the current generator -VB and +VB is 62 V via resistor R28. 16 V alternating voltage for IC20, and hence for the measurement evaluation, are used to produce the internal clock frequency of approx. 64 kHz. A power supply of 12 V, +12 V is available for the analog circuits. The voltage for the stirrer motor is generated by IC24, amplified by power transistor Q5 and supplied to the CN2 connector. The offset voltage 3.5 V for FET Q8 can be adjusted with potentiometer VR1. Processor board The processor board incorporates the following functions: - Circuitry for control of the preamplifier board - Software for evaluation of the measurement results - Monitor programs for the display and for the keypad inquiry - Control functions for the thermal printer and its control - Real-time clock - Reset circuit - Control of the METTLER DO337 Drying Oven The clock frequency of 8 MHz is generated by quartz crystal 1. This component contains an oscillator, divider module and buffer and drives the CPU (IC22 MOS version of the Z880). IC16 and IC17 are used for address and data storage. The PLD component (Programmable Logic Device)(IC14, chip enable) selects the addresses for ROM 1 - ROM 3 and RAM 1 - RAM 2. The ROM chips ROM 1 and ROM 3 contain the monitor programs, the methods, the evaluation programs and the control for the thermal printer (without character set for the thermal printer). The clock frequency of 6 MHz for the thermal printer is generated in quartz crystal 6. CPU2 controls the course of printing and stores the rapidly accumulating data in RAM 3 to avoid data loss. ROM 4 contains the character set for the thermal printer. The heating element drivers are ICs 2 and 4. The motor current for the thermal printer is generated by IC1 and transistor Q2. The speed of the printout is set using potentiometer VR1. IC12 is the real-time clock for the time and the calendar. The time function as well as the customer's specific method configurations and sample data are supported by the NiCd rechargeable battery. RAM 1 and RAM 2 are the memories for the methods, configurations and sample data. IC32 contains the necessary components for the power ON reset circuit. The data interchange between display and keypad is controlled directly by CPU-IC22. IC19 forms the buffer storage and driver for the data from and to the METTLER DO337 Drying Oven. The data are transmitted in machine code. IC19 also generates the frequency for the buzzer BZ (approx. 1 kHz). The stable 5 V voltage for the digital components is generated in IC1 and the 24 V voltage for the motor of the thermal printer in IC2 on the rectifier board ES-105136.
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Contents
1. 1.1 1.2 2. 2.1 2.2 3. 3.1 3.2 4.
Page
Checklist maintenance .............................................................................................. Visual inspection ....................................................................................................... Parameter check ........................................................................................................ Checklist service ...................................................................................................... Visual inspections ...................................................................................................... Final work steps ........................................................................................................ Service mode........................................................................................................... Cell test ....................................................................................................................
3 3 3 6 6 8 9 9
Printer test ................................................................................................................. 11 Function test............................................................................................................. 13
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1.
1.1
Caution
Checklist maintenance
Visual inspection
The instrument must not be opened for the following checks. Check power cable. Check all signal sockets for firm seating and cleanliness. Check all screws are tight. Check keypad for mechanical damage, distortions, contamination by chemicals and adhesion of the membrane in the corners. Check transparency of the display. Check burettes and sensors for contamination by chemicals. Check the titration cell for contamination. Check mounting of the detection electrode and the sensor. Check mounting of the titration cell. Check overall condition of the plastic housing (dirt, cracks, discoloration, scratches).
1.2
Parameter check
Print out all methods and parameters or inquire manually and note down. Separate balance from DL37 KF Coulometer. If a METTLER DO337 Drying Oven is attached, do connect this. Switch on DL37 KF Coulometer. Print out methods and parameters with the PRINT key. The printout must be regular and the printed image deep. If the Size parameter appears, the battery is discharged (see operating instructions of METTLER DL37 KF Coulometer). Check the stirrer functions Press PRE-TIR key. The magnetic stirrer revolves, the background value changes. Press the STIRRER key. The magnetic stirrer must revolve. Actuate settings 1 - 9 of the SPEED key. The magnetic stirrer must revolve at the specified set speed. Press the STIRRER key again. The magnetic stirrer should cease revolving. not dis-
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Check method functions Press METHOD key. Select methods 1 - 5. All numbers 1 - 5 must be capable of being changed. Check parameter functions Select method 2. Select TITR.PARA and change all parameters. Clear at least one parameter with the CLEAR key. Check alarm and error messages Unplug connection of double platinum pin electrode. The message Electrode open, short must appear. Unplug red plug-in connection of the iodine generator. The message CURRENT ERROR must appear. Remove paper from printer. The message Paper empty must appear. Perform function test with attached METTLER DO337 Drying Oven Select method 3. In the menu, change the parameter Limit;sec to 20 seconds using the TITR.PARA key. Change the parameters Back;sec?, Sampler;se c ? and Cell;se c ? to 20 seconds. In the menu set the parameter Oven;Te m ? to 100 C with the TITR.PARA key. After the method selection, the temperature in the METTLER DO337 Drying Oven must rise immediately and after approx. 5 minut es level out and stabilize around the set value. Overshooting by approx. 10 is admissible. Check version number 000 and the ENTER key causes a brief display (around 2 seconds) of the version number with Ver. XX.XX.XX.AA. Check the weight transfer Attach balance with RS-232C interface to the balance input of the optional interface. Interface parameters: Transmission rate 2400 baud, even parity, 1 start bit. Transfer a weight using the SIZE key. Check computer interface Connect RS-232C computer interface to the computer. C
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Check titration cell for leaks Load all default values with method 99. Select method 2. Start background measurement with the PRE-TITR key. After 1 hour, the background value must be < 0.1 g/s. If this value is not reached, dry titration cell in a desiccator or with a hair dryer and check for leaks. Check reproducibility (DL37 only) Perform three measurements with 250 Final work steps Load customer parameters. Perform sample data transfer. L DL37 check solution added using a microsyringe.
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2.
2.1
Checklist service
Visual inspections
Check setting of voltage selector is correct. Disconnect all attached devices from DL37 KF Coulometer. Switch on the DL37 KF Coulometer and select the service program in the menu. Start service program by entering PRE TITR 111 Enter. Print out all methods and parameters. Select method 80, a special test method. The text 2 Check <ENTER> appears in the display. Default values, which can be changed, appear in the display (see table below). Wrong values can have a negative influence on the course of the titration! Display Ready Lev. ? Short Lev. ? Open Lev. ? Over Titr. ? Meas Over ? Current ? Conc. Nbr. ? Pot Ep Lev. Para 1 ? Para 2 ? Para Note Entry of the identical value allows exit from the hidden functions. A beep confirms return to the normal mode. The parameters can be printed out with the PRINT key. Exit the service mode by entering RESET. Note If no parameters have been changed, the DL37 is in the operational readiness condition. Value 10.0 30.0 600.0 150.0 100.0 20.0 4 200 0.0 0.0 0.0 Minimum value when Pt electrode short circuited Extreme value on break in Pt electrode Threshold value on overtitration Lower threshold value of the measurement Current through the Pt electrode Not used Threshold value for end-point voltage Not used Not used Not used Meaning
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If parameters have been changed, the default values must be entered. The following procedure sets all parameters to the default values: Select Method 99 Enter. Switch off instrument. Wait at least 10 seconds. Switch on instrument again. All methods and parameters now have the default setting. Note Reenter the customers values for the methods and all other parameters (see operating instructions of DL37 KF Coulometer). Use of the test instrument A titration routine can be reconstructed with the aid of the test instrument (electrode simulator): Unplug generator connector and platinum sensor. Attach test instrument. Turn potentiometer completely to the right. Switch on DL37 KF Coulometer. Press PRE-TITR key. Select FUNCTION 7. Press ENTER key. The display shows: Pot,mV. Set voltage value on potentiometer to 350 mV for Software Version 3.1AA. Set voltage value on potentiometer to 250 mV for Software Version 1.7AA / 1.9AA. No end point may be detected as this voltage does not correspond to the end-point voltage of 200 mV. Set voltage to 200 mV by slowly turning the potentiometer. The end of the titration is signalled by a beep. By slowly turning the potentiometer further, the voltage becomes less. At a voltage of 150 mV, the warning Over Tit appears. Summary If the DL37 KF Coulometer reacts as described above, with the appropriate values, the hardware of the instrument is functioning properly. Possible error sources if behavior different from above: Major leak (background level) owing to water in silicone grease Dirty titration cells Impure reagents The visual inspection is performed in the same manner as that for the maintenance check, see section 1.1.
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2.2
Final work steps
Reread error codes in the operating instructions of the DL37 KF Coulometer. Perform the parameter check, section 1.2, before opening the instrument. In many cases, this maintenance check and any error codes allow the error to be localized. Measure all voltages. Perform printer test, see service mode chapter B3. On completion of the maintenance check, disconnect the power plug. Close the DL37 KF Coulometer and reconnect to power supply. Switch on the DL37 KF Coulometer.
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3.
Service mode
The service mode comprises two main tests: - the cell test and - the printer test. In the cell test, the water tightness of the titration cell, the measurement potential and the condition of the reagents are checked. The printer test is a function test of the built-in thermal printer.
3.1
Cell test
Use of hidden test functions: The DL37 KF Coulometer is in the standby mode. Press PRE-TITR key. All entries must be confirmed by pressing the ENTER key. Entry 000 000 .0 Value e.g. 87AA g/sec Meaning ROM version (approx. 2 seconds) Stability of the current change shows whether titration cell is leaking. The value should be within the set background value. In Function 7 with 2 x ENTER Unstable values indicate exhausted reagents.
0002. . 000 .1
2 Drift & level display Stability of the background measurement to 3 places Generator current
000 .6
Value of the last background measurement. Value should be within the set background value (e.g. 0.1 g/sec). Segment test
000 .7
Blocks the display
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Note With Software Version 1.7AA / 1.9AA To quit the above test routine or to proceed to the next step, enter the following key sequence: Example Reset 000.1 Enter Example 000.0 Enter 000.0 Enter The stability is displayed. Display returns to the normal mode.
A repeated beep of the built-in buzzer confirms the normal mode.
With Software Version 3.1AA To quit or to proceed into the next step enter the new key sequence: Example 000.0 Enter 000.1 Enter The stability of the current generator is displayed. The stability of the back ground level is displayed.
Cleaning of the cell and replacement of reagents are described in detail in the DL37 KF Coulometer operating instructions. Note Extended measurement possibility in the function for measurement of the water tightness of the titration cell, the functioning of the Pt sensor and the condition of the two reagents: Example 000.2 Enter Function 7 Enter Enter
Pot., mV Display of the background value and the measurement potential
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Note With Software Version 1.7AA / 1.9AA To quit the above test routine or proceed or to go to the next step in the routine, enter the following key sequence: Example Reset 000.2 Enter
A repeated beep of the built-in buzzer confirms the normal mode.
With Software Version 3.1AA With the following sequence skip to the next step. To go to the next step in the routine, enter the following key sequence. Example 000.2 Enter 000.1 Enter Drift and Background Level is displayed. Stability of the Background Levels is displayed.
3.2
Printer test
CPU4 and Software Version 1.7AA / 1.9AA / 3.1AA The quality of the printout and the uniformness of the printing image is tested or adjusted in the printer test. Open DL37 KF Coulometer. Place housing cover on right. Switch DIP switch No. 4 on the processor board to ON. Ensure that the printer paper is inserted properly. Briefly press reset knob on processor board. The thermal printer outputs a neat test printout of length around 30 cm within approx. 45 seconds. On completion of the printer test, reset DIP switch No. 4 to OFF. If the thermal printer outputs not a neat test printout, the printer frequency must be checked and adjusted (See chapter D2.2)
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CPU5 and Software Version 3.1AA The quality of the printout and the uniformness of the printing image is tested or adjusted in the printer test. Open DL37 KF Coulometer. Place housing cover on right. Switch DIP switch No. 4 on the processor board to ON. Ensure that the printer paper is inserted properly. Briefly press reset knob on processor board. On completion of the printer test, reset DIP switch No. 4 to OFF. If the thermal printer outputs not a neat test printout, the printer frequency must be checked and adjusted (See chapter D2.3).
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4.
Function test
Perform function test Switch on DL37 KF Coulometer. All segments of the illuminated display must light up. Press PRE-TITR key. The stirrer must revolve. Press STIRRER key. The stirrer should cease revolving. Press STIRRER key. The stirrer must revolve again. Press SPEED key. Enter numeric values 1 to 9 one by one. The stirrer must revolve faster with increasing numeric value, but should not touch the titration cell at the highest speed (setting 9). Press PRINT key. A paper advance of 7 lines must start. The printout should show no streaks. Select a method. Press PRINT key. The method parameters are printed out. The print quality of the printout must be good. The numbers must not be squabbled. The paper should not streak at the side. Take paper roll out holder. The message Paper out must be outputted.
Check data transmission Without balance connection Press SIZE key. Enter a sample weight manually. Enter two different weight data sets. The built-in tare calculator must be able to calculate the net weight. With RS interface and AE, AT, PJ, PM or PE balance attachment Connect balance to interface. Press SIZE key. The sample weight is now read in and must appear on the display.
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Troubleshooting
Contents
1. 2. 2.1 2.2 2.3 2.4 3.
Page
Fuses ....................................................................................................................... Test points ................................................................................................................ Processor board ........................................................................................................ Preamplifier board ..................................................................................................... Power supply board ................................................................................................... Interface board .......................................................................................................... Troubleshooting ........................................................................................................
3 4 4 5 5 6 7
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1.
Fuses
Voltage selector Line voltage
Connection to METTLER DO337 Drying Oven
The line-side fuse values:

AC Voltage 90 - 121 V 103 - 132 V 198 - 242 V 216 - 264 V Fuse 3.15 A, slow-blow 3.15 A, slow-blow 1.6 A, slow-blow 1.6 A, slow-blow Hz 50/60 50/60 50/60 50/60
Flat screwdriver Voltage selector
V V V V
Various semiconductor fuses are on the boards. They are marked on the circuit diagrams with EMF. Replacement is possible only in the factory.
Fuses
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2.
Test points
The following sections show the tables of all test points for the processor, the preamplifier, the display, the power supply and the interface boards.
2.1
Processor board
Signal GND2 GND1 GND test point Clock frequency Clock frequency 3, 6, 9, , RESET keys 2, 5, 8 keys PRINT key 0, 1, 4, 7 CLEAR, ENTER keys STIRRER key SIZE, RESULT keys TITR.PARA, METHOD 5.0 V 2.5 V Pulse train Target value 0V 0V 0V 8 MHz 4 MHz Tolerance Remarks Reference point for 24 V Reference point for 5 V Reference point for measurements Reference to CP0 Reference to CP0 Reference to CP0 Reference to CP0 Positive pulse Negative pulse train Reference to CP0 Reference to CP0 Reference to CP0 Reference to CP0 With DL37 switched on With DL37 switched off On printer start
Test point JP1 JP5 CP0 JP3 CP2 IC22 Pin 1 IC22 Pin 2 IC22 Pin 4 IC22 Pin 5 IC22 Pin 6 IC22 Pin 7 IC22 Pin 8 Battery IC4 Pin 12
The keys of the membrane keypad can be tested at IC22 using an oscilloscope. Reference point is CP0. Test points at the connectors
Test point CN9 CN10 CN10 CN10 CN8 CN8 Pin A15 -A16 Pin 1-2 Pin 1-3 Pin 2-3 Pin 1-5 Pin 3-4
Target value 17 VAC 17 VAC 17 VAC 35 VAC 5 VDC 24 VDC
Tolerance 10 % 10 % 10 % 10 % 5 % 5 %
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2.2
Preamplifier board
Signal 12 VDC +12 VDC 0 VDC +12 VDC 5 VDC 0 VDC 62 VDC 2.5 V 2.5 VDC 25 Hz sinus 5 MHz 100 kHz Target value 12 VDC 12 VDC Reference GND 12 VDC 5 VDC Reference GND 62 VDC 2.5 V 2.5 V 1.0 V Tolerance 5% 5% 5% 5% 5 V 10 mV 0.75 V 0.6 V -1.5 V Remarks Analog voltage Analog voltage Analog voltage Analog voltage Driver voltage See adjustment 2, section D, chapter 2.1 See adjustment 1, section D, chapter 2.1 Electrode voltage, section B, chapter 2.1 Clock frequency Clock frequency
Test point Anode D3 Anode D4 Cathode D3 Anode D10 Anode CP5 Cathode CP5 VB - +VB CP2 -CP4 CP2-R41 IC26/6 -cath. D3 JP1-cath. D3 JP2-cath. D3
Test points at the connectors
Test point CN2 CN3 CN3 CN3 CN4 CN4 CN4 Pin 1-2 Pin 1-2 Pin 1-3 Pin 2-3 Pin 1-2 Pin 3-4 Pin 3-5
Target value
Remark / Tolerance See stirrer test, section B, chapter 1.2.
17 VAC 17 VAC 35 VAC 35 VAC 16 VAC 16 VAC
10 % 10 % 10 % 10 % 10 % 10 %
2.3
Power supply board

Target value Pin 1-5 Pin 3-4 5 VDC 24 VDC Tolerance 5 % 5 % Remark On the processor board On the processor board
Test point CN8 CN8
6/98
C-5
Troubleshooting
DL37
2.4
Interface board
Signal 12 VDC +12 VDC 0 VDC 1.22 MHz Target value 12 VDC 12 VDC 5V Tolerance 5% 5% Remarks Interface voltage Interface voltage GND Clock frequency GND
Test point Anode D2 Cathode D1 Cathode D2 IC2 Pin 23 IC2 Pin 23
Test points at the connectors
Test point CN1 CN3 Pin A15-A16 Pin B15-B16
Target value 17 VAC 17 VAC
Tolerance 10 % 10 %
Additional measurements of the data transmission can be performed with the break box directly at connectors CN2 and CN3.
C-6
6/98
DL37
Troubleshooting
3.
Troubleshooting
The following error messages are shown in the display of the DL37 KF Coulometer:
Error message No display Possible cause Voltage selector Fuses Poor contacts Analog board faulty Digital board faulty Power supply board faulty Plug-in connection Error in ADP Rectification
Check all plug-in connections. Measure voltages. Measure voltages. Measure voltages. Check connection cable. Check all plug-in connections. Measure voltages.
ADP Error!
Current Error!
Current anode short circuited Analog board faulty Break in electrode cable
Check anode for short circuit. Check analog board with electrode tester. Check detection electrode, cable and connector. Check detection electrode, cable and connector.
Elect Open!
Elect Short!
Electrode tips short circuited
Note It is important to perform a simulated titration with the electrode tester as the first step. Many error messages can be caused by both a fault in the system and an error in the application (e.g. exhausted chemicals). Additional error messages, see operating instructions of DL37 KF Coulometer. Check stirrer motor and power supply Open DL37 KF Coulometer. Disconnect stirrer motor cable at connector CN2. Attach digital voltmeter to connector CN2. Switch on stirrer voltage with the STIRRER key. Voltage value with SPEED 1 key: 0.6 - 0.8 V Voltage value with SPEED 5 key: 2.1 - 2.4 V Voltage value with SPEED 9 key: 4.2 - 4.6 V
6/98
C-7
Troubleshooting
DL37
C-8
6/98
DL37
Repairs
Contents
1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 2. 2.1 2.2 2.3
Page
Corrective maintenance ............................................................................................ Changing the preamplifier board .................................................................................. Removing the thermal printer ....................................................................................... Removing the magnetic stirrer motor ............................................................................ Changing the display board ........................................................................................ Dismantling the membrane keypad .............................................................................. Replacing the power transformer .................................................................................. Changing the voltage selector ...................................................................................... Changing the power switch .........................................................................................
3 3 4 5 6 7 8 9 9
Changing the power line filter ...................................................................................... 10 Changing the rectifier board ........................................................................................ 11 Changing the interface board and processor board ........................................................ 11 Checking and calibrating the boards .......................................................................... 12 Calibrating the preamplifier board ................................................................................ 12 Adjusting the processor board (CPU4) ......................................................................... 15 Adjusting the processor board (CPU5) ......................................................................... 16
6/98
D-1
Repairs
DL37
D-2
6/98
DL37
Repairs
1.
1.1
Corrective maintenance
Changing the preamplifier board
Unscrew the four screws (1) at the rear of the instrument next to the heat sink.
Slowly and carefully pull out rear panel halfway approx. 5 cm. Undo the plug-in cable connections at connectors CN5, CN1, CN3 and CN4 in that order. Now take out preamplifier board completely and change. Perform installation of the preamplifier board ES-105132 in reverse order. Ensure the 4 screws are firmly tightened. Adjust new preamplifier board, see section D, chapter 2.1. Reinstall metall shielding
6/98
D-3
Repairs
DL37
1.2
Removing the thermal printer

2 For replacement of the thermal printer, do not open DL37 KF Coulometer completely. Remove printer paper (3). Unscrew the two screws (2) of the printer housing (4). Lift up printer housing slightly at rear and press forward. Take off printer housing.
Undo four nuts (5) and carefully remove the retaining plate. Remove printer (6).
5
Unplug flat cable from intermediate board. Install in reverse order.
4 5 6
Adjust printing quality as described in chapter D2.2 or D2.3.
4 5 6
D-4
6/98
DL37
Repairs
1.3
Removing the magnetic stirrer motor

Remove titration cell from its holder. Unscrew two screws at holder. Remove holder of titration cell. Note
2 1 1
The mounting plate of the magnetic stirrer motor must not be removed! Open DL37 KF Coulometer at base. Withdraw stirrer motor cable. Unscrew two hex socket-head screws (2 mm) of the magnet support plate. Loosen magnet support plate from the motor shaft and remove. Caution The magnetic force is active! The magnet will splinter if loose objects fall on it. Unscrew the four screws of the motor mounting plate. Take out the magnetic stirrer motor from above. Install new magnetic stirrer motor. Mount magnet support plate and align flush with the end of the motor shaft. Tighten screws. Installation in reverse order.
6/98
D-5
Repairs
DL37
1.4
Changing the display board

Remove titration cell from its holder. Open DL37 KF Coulometer at base. Disconnect all cable connections to top half of DL37. If present, disconnect ground connection of the display board. If present unscrew and remove metall case from display. Unscrew the metal plate with the display. Caution The plate on the display board must be on the side of the ground connection. Remove display. Clean front glass if necessary. Install new display board in reverse order.
D-6
6/98
DL37
Repairs
1.5
Dismantling the membrane keypad

Remove titration cell from its holder. Open DL37 KF Coulometer at base. Disconnect all plug-in cable connections to top half of DL37 KF Coulometer. Dismantling the membrane keypad Remove membrane keypad. Carefully remove any residual adhesive from support surface of membrane keypad at housing with ligroin. Clean the front glass if necessary. Installing the membrane keypad Remove both protective films at the rear of the membrane. Align keypad membrane flush at bottom and at one side and stick on. When sticking on membrane keypad, press down carefully. Pressing and smoothing down eliminates air bubbles.
6/98
D-7
Repairs
DL37
1.6
Replacing the power transformer

Remove titration cell from its holder. Open the DL37 KF Coulometer. Disconnect plug-in cable connection CN1 at rectifier board. Disconnect plug-in cable connection CN4 at preamplifier board. Disconnect plug-in cable connection CN11 at processor board. Unsolder the transformer connections of the line voltage selector.
Unscrew transformer from bracket. Screw on new transformer. Reconnect plug-in cable connections. The plug-in cable connections CN10 and CN11 are implemented in parallel and hence interchangeable. Solder on transformer connections at line voltage selector as shown in the wiring diagram. (See chapter D1.9) Reassemble in reverse order
D-8
6/98
DL37
Repairs
1.7
Changing the voltage selector

Remove titration cell from its holder. Open the DL37 KF Coulometer. Unsolder connections from line voltage selector and power supply input. Press the plastic latches together and remove along with the line voltage selector. Install new voltage selector. Solder on connections as shown in the wiring diagram. (See chapter 1.9)
I 0
1.8
Changing the power switch
Remove titration cell from its holder. Open the DL37 KF Coulometer. Disconnect the four cables at the power switch. Press the plastic latches at the power switch together and remove along with the power switch. Solder on connections as shown in the wiring diagram.
6/98
D-9
Repairs
DL37
1.9
Changing the power line filter

Remove titration cell from its holder. Open the DL37 KF Coulometer. Unscrew the eight screws on rear panel.
T blue T yellow T white
Unscrew the four screws on baseplate. Unsolder the transformer connections at line voltage selector.
4 PS brown
T orange T red 1 PS blue 5 PS brown
Lift up transformer bracket and unscrew power line filter. Reinstall power line filter. Solder on power supply connections as shown in the wiring diagram. Reassemble instrument in reverse order.
2 PS blue
OUT PF blue IN PF blue
OUT PF brown IN PF brown
green/white Ground
T PS PF
= Transformer = Power switch = Power line filter
D-10
6/98
DL37
Repairs
1.10 Changing the rectifier board

Remove titration cell from its holder. Open the DL37 KF Coulometer. Disconnect plug-in cable connections CN1 and CN4 at the rectifier board. Unscrew two screws on baseplate. Change rectifier board. Reconnect the two plug-in cable connections.
1.11 Changing the interface board and processor board

Remove titration cell from its holder. Open the DL37 KF Coulometer. Unscrew two screws at side of DL37. Remove interface board. Disconnect all plug-in cable connections of processor board. Unscrew two screws at processor board. Take out the processor board. Insert new processor board. Insert new interface board. Screw on interface board. Screw on processor board. Connect all plug-in cable connections. Adjust processor board.
6/98
D-11
Repairs
DL37
2.
Note
Checking and calibrating the boards
The replacement boards are adjusted by the manufacturer. The adjustment after replacement is a necessary check.
2.1
Calibrating the preamplifier board
Working aids DVM, 3 1/2 digits/impedance >10 M Test instrument ME-105127 Short test cable with clamps at both ends
rot / red 1 / 5 W 0,1% 50 ppm
1 3
1F 630 V
Potentiometer 20 k lin.
weiss / white
Schematic of test instrument Procedure Switch off DL37 KF Coulometer. Attach the test instrument in place of the titration cell. Undo the four screws at the rear of the instrument next to the heat sink. Slowly and carefully pull out rear panel halfway. Take out preamplifier board halfway. Disconnect connector CN1. The other connectors must remain plugged in.
D-12
6/98
DL37
Repairs
Preamplifier board
VR1
R41
VR42
Offset current generator adjustment Attach the DVM to test point CP2 (minus side). Attach resistor R41 (positive voltage). Switch on the DL37 KF Coulometer. Allow the DL37 KF Coulometer to warm up for 15 minutes. The voltage should reach a value between 1.5 V and 3.5 V. Voltage outside range 1.5 V to 3.5 V: Adjustment with potentiometer VR1. Adjustment of the potentiometer is very sensitive.
6/98
D-13
Repairs
DL37
Reference voltage adjustment Switch off the DL37 KF Coulometer. Attach DVM between test point CP4 (plus) and CP2 (minus). Switch on the DL37 KF Coulometer. The voltage should be approx. 0 mV. Switch off the DL37 KF Coulometer. Short circuit the test points CP5 and CP6 with a short test cable. The voltage on the DVM should be 2.5 V 1.0 mV. Adjust the voltage with potentiometer VR2. Switch off the DL37 KF Coulometer. Disconnect shorting cable and DVM.
Checking the safety circuit Attach cable of electrode test instrument in place of titration cell. Connect test point CP2 and anode side of diode D8 with a test cable. Switch on the DL37 KF Coulometer. The safety relay RY1 must switch audibly. Switch off the DL37 KF Coulometer. Disconnect cable connections.
Checking the measurement current Attach DVM to connection of the current generator. Connect test points CP5 and CP6 with a test cable. Connect test point CP2 and anode side of diode D8 with a test cable. Note Ensure short cable connection ! Switch on the DL37 KF Coulometer. The voltage at the measuring resistor should be 40 mV 0.5 mV. If this voltage is not found: - Check reference voltage. (See Reference voltage adjustment) - Replace preamplifier board.
D-14
6/98
DL37
Repairs
2.2
Adjusting the processor board (CPU4)
Real time clock adjustment Instruments needed: Frequency counter or oscilloscope Set frequency counter to time measurement. Connect frequency counter between CP1 and CP0 (ground). Adjust trimmer VC1 until the display of the frequency counter shows 61035.16 ns or 16.384 kHz.
Printing quality adjustment Switch off the DL37 KF Coulometer. Set DIP switch No. 4 to ON. Switch on the DL37 KF Coulometer. Printer starts. Printout is interrupted with RESET key. Press RESET key again. Printer starts. Measure time for all characters to be printed out. Time should be around 45 seconds. Print quality of printout is not perfect or image is squabbled: Adjust potentiometer VR1.
VC1 Real Time Clock adjustment
VR1 Printer adjustment
6/98
D-15
Repairs
DL37
2.3
Adjusting the processor board (CPU5)
Real time clock adjustment Instruments needed: Frequency counter or oscilloscope Set frequency counter to time measurement. Connect frequency counter between CP1 and CP0 (ground). Adjust trimmer VC1 until the display of the frequency counter shows 100.00 S or 100 kHz 0.200 kHz.
Printing quality adjustment Switch off the DL37 KF Coulometer. Set DIP switch No. 4 to ON. Switch on the DL37 KF Coulometer. Printer starts. Printout is interrupted with RESET key. Press RESET key again. Printer starts. Print quality of printout is not perfect or image is squabbled: Connect frequency counter to CP5 and CP0 (Ground) Adjust potentiometer VR1 to a reding of 100.000 kHz 0.200 kHz.
VC1 Real Time Clock adjustment
VR1 Printer adjustment
D-16
6/98
DL37
Service Bulletins
Is my service manual really up to date ?

At the bottom right of the title page you will find the date of issue. If you know the date of the latest edition, you can thus see whether your service manual is up to date. If this is not the case, the latest service bulletin has not been filed. (The service bulletins represent a continuous supplement to the service manual and keep it up to date.) The service bulletin always includes a new title page for the service manual, new pages and pages to be exchanged, as well as a new contents page for section E. All these documents have the same, latest date of issue at the bottom of the page. First edition of the METTLER DL37 KF Coulometer service manual: March 1992 (03/92) This service manual replaces the service manual ME-704726, edition March 1992.
Contents section E
There are no Service Bulletins at present
Date of issue
6/98
E-1
Service Bulletins
DL37
E-2
6/98
DL37
Data section
Contents
Page
3 5 7 9
Overall diagram ES-105130 .................................................................................................. Wiring diagram ES-105133 ................................................................................................... RS232C-Interface board ES-105134 ...................................................................................... Power supply board ES-105136 .............................................................................................
Display board ME-105027 ..................................................................................................... 11 Power supply board ME-105031 ............................................................................................ 13 RS232C-Interface board ME-105096 ...................................................................................... 15
Service Manual ME-704926
6/98
F-1
Data section
DL37
DL37
F-3
Overall diagram ES-105130
METTLER TOLEDO reserves all rights in this document and in the subject thereof. By acceptance of the document the recipient acknowledges these rights and undertakes not to publish the document nor the subject thereof in full or in part nor to make them available to any third party without METTLER TOLEDOs prior express written authorisation nor to use it for any purpose other than for which it was delivered to him.
Data section
DL37
DL37
Wiring diagram ES-105133

F-5
Data section
DL37
DL37
F-7
RS232C-Interface board ES-105134
Data section
DL37
DL37
F-9
Power supply board ES-105136
Data section
DL37
DL37
F-11
Display board ME-105027
Data section
DL37
DL37
F-13
Power supply board ME-105031
Data section
DL37
DL37
F-15
RS232C-Interface board ME-105096
Data section
DL37

DL37 SM e 710142

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Service Manual METTLER TOLEDO KF-Coulometer DL37

Checklist maintenance Checklist service Service mode Function test

Fuses Test points Troubleshooting

Corrective maintenance Calibration and checking the boards

Circuit and board component diagrams

Service Manual ME-704726A

Service Manual ME-704726A

Service Manual ME-704726A

2.1.1 Software changes

2.1.2 Software changes overview

Service Manual ME-704726A

2.1.3 Hardware changes

2.1.4 Software compatibility

Service Manual ME-704726A

Exploded view diagrams

Service Manual ME-704726A

Service Manual ME-704726A

Service Manual ME-704726A

Service Manual ME-704726A

Spare parts list

Service Manual ME-704726A

Part number Non CE-Version 105002 88549 88548 88554 88553 -

Service Manual ME-704726A

Service Manual ME-704726A

Drying tubes of titration cell

Detection electrode (double platinum pin electrode)

Titration cell Holder of titration cell

Service Manual ME-704726A

Interface for electronic balance (option)

Computer interface (RS-232C) (option)

Service Manual ME-704726A

6.2.1 Hardware description

Service Manual ME-704726A

Service Manual ME-704726A

Service Manual ME-704726A

Service Manual ME-704726A

Printer test ................................................................................................................. 11 Function test............................................................................................................. 13

Service Manual ME-704726A

Service Manual ME-704726A

Service Manual ME-704726A

Service Manual ME-704726A

Service Manual ME-704726A

Service Manual ME-704726A

Service Manual ME-704726A

Final work steps

Service Manual ME-704726A

Blocks the display

Service Manual ME-704726A

A repeated beep of the built-in buzzer confirms the normal mode.

Pot., mV Display of the background value and the measurement potential

Service Manual ME-704726A

A repeated beep of the built-in buzzer confirms the normal mode.

Service Manual ME-704726A

Service Manual ME-704726A

Service Manual ME-704726A

Service Manual ME-704726A

Service Manual ME-704726A

Service Manual ME-704726A

Voltage selector Line voltage

Connection to METTLER DO337 Drying Oven