KERN & Sohn GmbH
Ziegelei 1
D-72336 Balingen
E-Mail: info@kern-sohn.com
Tel: +49-[0]7433-9933-0
Fax: +49-[0]7433-9933-149
Internet: www.kern-sohn.com
GB
Service Manual
Electronic Compact Balance
Page 2
KERN GAB/GAS
Version 1.1 11/2007
GAB/GAS-SH-e-0711
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Read this manual thoroughly and do not perform installation, operation, maintenance, or
inspection unless you fully understand all of the contents.
Keep this manual in a safe place where you can refer to it easily while installing, operating, and
carrying out maintenance or inspections.
OUTLINE
• Purpose of this manual
This manual is edited for the authorized servicing personnel and used when carrying out services and
maintenance of the machine.
• Relative manual
Refer to the operation manual for ususal operations.
• Symbols used in this manual
1. Warning symbols
Symbol Meaning
Indicates information that, if not avoided, is likely to result in loss of life or serious
injury.
Indicates information that, if not avoided, may result in loss of life or serious injury.
Indicates information that, if not avoided, could result in relatively serious or minor
injury, damage to the machine or faulty operation.
2. Explanatory symbols
Symbol Meaning
Indicates information to call or emphasize for attention to the note.
Indicates the reference page.
Indicates information to help understanding.
• Readers of this manual
This manual is edited for the servicing personnel. Use by other personnel is not permitted.
• Note
This manual may be revised in accordance with modification when made in the machine.
All rights are reserved. Copying any part of this manual is prohibited without our permission.
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Contents
Chapter 1 Product Overview.........................................................................................4
1.1 Product Overview..............................................................................................................4
1.2
Standard Specifications ....................................................................................................4
1.3 Appearance.......................................................................................................................5
1.4 Operation Panel ................................................................................................................6
1.5 Outer Dimensions .............................................................................................................7
Chapter 2 Test Mode......................................................................................................8
2.1 Operation ..........................................................................................................................8
2.1.1 Test Mode Flow ...................................................................................................................8
2.1.2 Key Functions (when setting value).....................................................................................9
2.1.3 Starting Test Mode...............................................................................................................9
2.1.4 Ending Test Mode................................................................................................................9
2.1.5 Memory Switch ....................................................................................................................9
2.1.6 C1 Mode – Country No. Setting.........................................................................................10
2.1.7 C2 Mode – Scale No. and Decimal point Setting ..............................................................11
2.1.8 C3 Mode – Span Adjustment.............................................................................................12
2.1.9 F Mode – Setting measuring conditions and EPROM clear ..............................................13
2.1.10 Error No. List......................................................................................................................14
Chapter 3 Hardware Configuration.............................................................................15
3.1 Mechanisms....................................................................................................................15
3.1.1 Small Size (3kg, 6kg).........................................................................................................15
3.1.2 Large Size (15kg, 30kg).....................................................................................................17
3.2 Electric Concerns............................................................................................................19
3.2.1 Block Diagram....................................................................................................................19
3.2.2 Board PS-005 ....................................................................................................................19
Chapter 4 Maintenance................................................................................................21
4.1 Disassembly Procedure (Small Size: 3kg • 6kg).............................................................21
4.1.1 Base Replacement.............................................................................................................21
4.1.2 Board Replacement ...........................................................................................................22
4.1.3 Load Cell Replacement .....................................................................................................23
4.2 Assembly Procedure (Large Size: 15kg • 30kg) .............................................................25
4.2.1 Base Replacement.............................................................................................................25
4.2.2 Board Replacement ...........................................................................................................26
4.2.3 Load Cell Replacement .....................................................................................................27
4.3 Troubleshooting ..............................................................................................................29
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Chapter 1 Product Overview
1.1 Product Overview
• The GAB/GAS Series is a digital scale which can be operated with two batteries.
• The large LCD with 25mm height is provided for the display.
1.2 Standard Specifications
KERN GAB 3K1DM GAB 6K2DM GAB 15K5DM GAB 30K10DM
Readability / calibration value 1 g / 2 g 2 g / 5 g 5 g / 10 g 10 g / 20 g
Weighing range 1.5 kg / 3 kg 3 kg / 6 kg 7.5 kg / 15 kg 15 kg / 30 kg
Warm-up time 10 minutes 10 minutes 10 minutes 10 minutes
Recommended adjustment
weight incl. category
3 kg (M3) 6 kg (M3) 15 kg (M3) 30 kg (M3)
Operating temperature - 5° C .... + 40° C
Humidity of air max. 80 % (not condensing)
Housing (B x D x H) mm 236 x 282 x 102 - 108 286 x 363 x 102 - 124
Weighing plate (w x d) mm 230 x 180 280 x 260
Weight kg (net) 2 3,2
KERN GAS 3K1DM GAS 6K2DM GAS 15K5DM GAS 30K10DM
Readability / calibration value 1 g / 2 g 2 g / 5 g 5 g / 10 g 10 g / 20 g
Weighing range 1.5 kg / 3 kg 3 kg / 6 kg 7.5 kg / 15 kg 15 kg / 30 kg
Warm-up time 10 minutes 10 minutes 10 minutes 10 minutes
Recommended adjustment
weight incl. category
3 kg (M3) 6 kg (M3) 15 kg (M3) 30 kg (M3)
Operating temperature - 5° C .... + 40° C
Humidity of air max. 80 % (not condensing)
Housing (B x D x H) mm 236 x 282 x 102 - 108 286 x 363 x 102 - 124
Weighing plate (w x d) mm 230 x 180 280 x 260
Weight kg (net) 2 3,2
Reverse display yes yes
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1.3 Appearance
F ront view
Rear view
Bottom view
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1.4 Operation Panel
ON/OFF key
TARE key
Selection key / auto power function
Zeroing key
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1.5 Outer Dimensions
Small size
Large size
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Chapter 2 Test Mode
The Test Mode is used for diagnosis and/or setting at maintenance service.
2.1 Operation
2.1.1 Test Mode Flow
Note: Press the memory switch at any time during test mode to record the data to the EPROM.
Then “P-EP” appears in the display.
TARE
TARE
Setup of Scale No.
Span adjustment
Setting measuring CONDITIONS
EPROM clear
MODE
ON/OFF
C2 XX
C3
F x x x
END
Program No. display
Setup of Country No.
START
L003
C1 X
TARE
TARE
TARE
TARE
TARE
MODE
ZERO
MODE
+
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2.1.2 Key Functions (when setting value)
Key Function
ON
OFF
- Use at TEST mode startup.
(Press this key while the TARE key is depressed.)
- Use at TEST mode end
ZERO
- Use when selecting digits.
TARE
- Press when fixing values after mode or data selection.
- Increments values for each press during data change.
MODE
- Press when entering C3 or F mode
(Tactile switch in the main circuit board)
Stores EPROM data set for each item of the C and F mode.
Memory
Switch
2.1.3 Starting Test Mode
Operation Display
1. Press and release the ON/OFF key while the TARE
key is depressed.
2. Release the TARE key.
2.1.4 Ending Test Mode
Operation Display
1. C mode / F mode status
2. Release the ON/OFF key after depressing for one
second or more.
2.1.5 Memory Switch
Operation Display
1. C mode / F mode status
2. Press the Memory Switch.
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2.1.6 C1 Mode – Country No. Setting
1) Country No. Table
Country No.
1 2 3 4 5 6 7
JPN ASIA
USA
AUS
CAM
EU
Item Data
Wei-
ght
Digit Bit
0 0 0 0 0 0 0 Start range
0: ±10%
1: ±2%
1 D0
0 0 0 0 1 0 0 Zero point mark
0: Lights on at true zero
1: Lights on at
Provisional zero
2 D1
1 0 0 0 1 0 0
Below true zero
indication
0: "___"
1: Negative value
4 D2
0 0 0 0 1 0 0
Cleaning tare
weight by pressing
ZERO key
0: No
1: Yes
8
100
D3
0 0 1 0 0 0 1
Decimal point
Indicator
0: "."
1: ","
1 D4
0 0 0 1 0 0 0
Over-scale
indication
0: BLANK
1: "OL"
2 D5
0 0 0 0 1 0 0 Tare subtraction
0: Not possible
1: Possible
4 D6
0 0 0 0 0 1 1
ZERO key during
tare subtraction
0: Possible
1: Not possible
8
10
1
D7
0 0 0 0 0 0 0
Stabilized,
re-stabilized
frequency
0: 5 times.
1: 8 times.
1 D8
0 0 0 0 0 0 0
Re-stabilization
Starting range
0: 2 times over
1: 4 times over
2 D9
0 0 0 0 0 0 0
Stabilized/restabilized range
0: 3 times
1: 5 times
4 D10
1 0 0 0 0 0 0
Section
adjustment
0: No
1: Yes (JAPAN)
8
10
2
D11
804 000 010 020 04E 080 090 ←Display of F mode Measurement Condition
2) Operation
Operation Display
1. Stating Test
2. Setup of Country No.
- To select the No., use the MODE key
- Example: ASIA=2
3. When the C2 mode is then required, press the TARE key.
- When finishing, press the Memory Switch to record the
data to the memory, and enter the Ending Test Mode.
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2.1.7 C2 Mode – Scale No. and Decimal point Setting
1) Scale No.[ X1 ] Table
X1 Specifications A/D Counts
1 3kg (2g/1g) Multi interval 30000 (20/10)
2 6kg (5g/2g) Multi interval 30000 (25/10)
3 15kg (10g/5g) Multi interval 30000 (20/10)
4 30kg (20g/10g) Multi interval 30000 (20/10)
2) Decimal point indication [ X2 ] Table
X2 Display
1 "0"
2 "0.0"
3 "0.00"
4 "0.000"
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3) Operation
Operation Display
1. Stating Test
X2 X1
2. Scale No. and Decimal point indication mode
- Press the [ TARE ] key → 1st digit flashes
- Example: ASIA 6kg (5g/2g) Multi interval X1=2, X2=4
2.1 Scale No. Setting
- Press the [ MODE ] key one time (
X1=2)
X2 X1
2.2 Decimal point indication Setting
- Press the [ ZERO ] key → 2
nd
digit flashes
X2 X1
- Press the [ MODE ] key three times (X2=4)
X2 X1
- When the C3 mode is required, press the TARE key.
- When finishing, press the Memory Switch to
record the data to the memory, and enter the Ending
Test Mode.
2.1.8 C3 Mode – Span Adjustment
1) Operation
Operation Display
1. Stating Test
2. Span Adjustment mode
2.1 Press the TARE key two times.
2.2 Press the MODE key → displays original A/D data
(The normal range for original A/D data is 1000 to
25000 counts).
2.3 Press the MODE key without load on the weigh platter
→ Approx. 5000 count is diplayed.
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2.4 Press the ZERO key if the count diverges from 5000
counts.
2.5 Put the weight same as weighing capacity on the
weigh platter, then press the MODE key → "CAL" is
displayed, then the A/D count becomes "35000" on
the display.
If the count diverges from 5000 counts, unload the
weight and repeat the operations as set out in 2.4 and
2.5.
2.6 When the C3 mode is required, press the TARE key.
- When finishing, press the Memory Switch to
record the data to the memory, and enter the Ending
Test Mode.
• “CAL” operation can not be performed unless zero-point adjustment is finished.
• “CAL” operation can not be performed unless the original A/D value exceeds
33300 counts when the weight is loaded.
2.1.9 F Mode – Setting measuring conditions and EPROM clear
• All data has been fixed according to country specifications.
• Altering data may not conform to weighing and measuring tests for a country.
• See 2.1.6 “C1 Mode-Country No. Setting” for Measurement Conditions Setup
Table.
1) Operation
Operation Display
1. Stating Test
2. Setting measuring conditions
2.1 Press the TARE key three times
2.2 Press the MODE key → The least significant digit blinks.
Whenever the MODE key is pressed, the required digit can
be selected.
2.3 Whenever the MODE key is pressed, the figure of the digit
which has blinked does the increment.
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3. EPROM clear
･ Any scene of F mode is possible.
3.1 Press the ZERO key and MODEkey. → "EP-C" then "C1-1"
is displayed.
At this point, writing in EPROM of change data in
F mode and the default value to EPROM clear
has not been completed. Push the memory
switch.
EPROM clear initializes Country No., Scale No.,
Zero, and Span adjustment values. It is
necessary to set it again.
↓
4. Writing in EPROM
･ Push the memory switch to memorize data.
After EPROM is cleared, if writing is performed in
EPROM without setting Country No., Scale No.
nor Zero/Span adjustment value, and the power
is turned on, "Err1" is displayed and it is not
possible to use the machine. Set C1, C2, and C3
again.
Data after EPROM is cleared
Mode Data Item
C1 1 JAPAN
C2 11 Scale No.= 3kg (2g/1g) Multi interval Decimal point indication= " 0"
C3 Zero point and span adjustment value and each approximate value
F 804 Measurement condition
2.1.10 Error No. List
Error No. Mode Item
Err1 At power ON EPROM unsetting or garbled data
Err2 At power ON Outside start range
Err3 Test mode
Outside range where zero point can be adjusted (original A/D 1000
count or less)
Err4 Test mode (Original A/D 25000 count or more)
Err5 Test mode
Outside span adjustment possible range (original A/D 33300 count
or more)
Err6 Normal mode Original A/D zero count or less
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Chapter 3 Hardware Configuration
3.1 Mechanisms
3.1.1 Small Size (3kg, 6kg)
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GAB/GAS 3kg/6kg
No. Parts Name Weighing Capacity Q'ty
1 PLATTER 1
2 PLATE: SUPPORT 2
3 LOAD CELL (CZL-6D-C3-5kg-1000) 3kg 1
3 LOAD CELL (CZL-6D-C3-10kg-1000) 6kg 1
4 CASE 1
5 BASE 1
6 FOOT: LEVEL 4
7 BATTERY: COVER 1
8 LUCENT: PLATE 1
9 SHEET: DISPLAY: FRONT 3kg 1
9 SHEET: DISPLAY: FRONT 6kg 1
10 SHEET: DISPLAY: REAR 1
11 SLEEVE 4
12 NAME PLATE: SPEC 3kg 1
12 NAME PLATE: SPEC 6kg 1
13 PUSH RIVET 2
14 PWB PS-005A 1
15 LEVEL UNIT 1
18 SCREW ST 4 x 14 4
19 SCREW M 6 x 25 4
20 WASHER 6 4
21 SPRING WASHER 6 4
22 SCREW M 4 x 12 8
23 SCREW ST 3 x 8 3
24 SCREW M 5 x 16 4
26 SCREW M 4 x 10 5
27 SCREW ST 4 x 10 2
30 CUSHION BATTERY 2
31 SCREW M 4 x 12 1
32 SHEET 2
33 BATTERY HARNESS 1
34 SPRING 1 1
35 SPRING 2 1
36 WASHER 5 4
37 E: RING 3 1
38 PRINTER GND CORD 1
39 FILTER 1
40 PROTECT:SHEET 1
Note: Parts number may change without notice due to product improvement.
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3.1.2 Large Size (15kg, 30kg)
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GAB/GAS 15kg/30kg
No. Parts Name Weighing Capacity Q'ty
1 PLATTER 1
2 CASE 1
3 LUCENT: PLATE 1
4 SHEET: DISPLAY: FRONT 15kg 1
4 SHEET: DISPLAY: FRONT 30kg 1
5 SCREW ST 3 x 8 3
6 PWB PS-005A 1
7 PRINTER GND CORD 1
8 SCREW ST 4 x 14 4
9 LOAD CELL (CZL-6D-C3-25kg-1000) 15kg 1
9 LOAD CELL (CZL-6D-C3-50kg-1000) 30kg 1
10 SCREW M 4 x 12 2
11 SCREW M 5 x 25 4
12 PLATE: SUPPORT 2
13 PLATE: A: COVER 1
14 SCREW M 4 x 10 9
15 FOOT: LEVEL 4
16 PROTECT: SHEET 1
17 E: RING 3 1
18
SCREW M 4 ｘ12
1
19 BATTERY: COVER 1
20 CUSHION BATTERY 2
21 SPRING 1 1
22 SHEET 1
23 LEVEL UNIT 1
24 SPRING 2 1
25 BASE 1
27 BATTERY HARNESS 1
28 FILTER: CORE 1
29 SCREW M 6 x 25 4
30 WASHER 6 4
31 SPRING WASHER 6 4
32 NAME PLATE: SPEC 15kg 1
32 NAME PLATE: SPEC 30kg 1
33 PUSH RIVET 2
35 SHEET: DISPLAY:REAR 1
Note: Parts number may change without notice due to product improvement.
- 19 - GAB/GAS-SH-e-0711
3.2 Electric Concerns
3.2.1 Block Diagram
3.2.2 Board PS-005
CN4
JP1
CN3
CN1
SW 5
JP3
CN6
JP2
JP4
GND
(Ｂ)
(Ｇ)
(W )
(R )
JP5
CN2
JP6
CN5
Load cell
(4 types depending on
weighing capacity
Batteries
GND connection
Main board PS-005
AC adaptor
(Option)
- 20 - GAB/GAS-SH-e-0711
Connector
CN1: AC adaptor input
Pin No. Function Remarks
2 AC adaptor power source DC 2.4 to 6.0V
3 GND (Circuit)
4 GND (Battery)
CN2: Battery input
Pin No. Function Remarks
1 GND (Battery)
2 Battery power source DC 2.2 to 3.2V
CN3: Not used
CN4: LCD display data output
CN5: Not used
CN6: Load cell input
Pin No. Soldering land Function Remarks
1 (R) Vcc DC5v
2 (W) GND GND
3 (G) IN+ Approx 2.5v
4 (B) IN- Approx 2.5v
5 GND GND GND
Jumper
JP1: Ferrite cut
JP2: Ferrite cut
JP3: Ferrite cut
JP4: Ferrite cut
JP5: Battery GN and Circuitry GND
JP6: Filter cut
Switch
SW5: EPROM Memory switch
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Chapter 4 Maintenance
4.1 Disassembly Procedure (Small Size: 3kg • 6kg)
The seal restricts the peel according to the country by a no report and doing as wanting
put it. Follow the relevant procedure for the respective countries.
4.1.1 Base Replacement
Disassembly procedure
1. Remove dry batteries when using batteries. Remove the AC adaptor when using the AC
adaptor.
2. Remove four foot levels.
3. Peel off the approval seal.
4. Remove the four M4×10 screws.
5. Lift the base, and pull out the battery harness from CN2 of main board PS-005.
Assembly procedure
1. Perform in reverse order to disassembly.
2. The approval seal material is a void seal. It is not possible to use it again. Use a new approval
seal.
KERN
- 22 - GAB/GAS-SH-e-0711
4.1.2 Board Replacement
1. Remove the load cell cable and grand cable using the soldering iron.
2. Remove the three ST3×8 screws where the board is fixed.
3. The board is fixed with four hooks and one lib as shown in the photo.
Press down the place shown by the arrow while pulling towards yourself, then remove the
hook 1 by sliding the entire board to the left and out.
4. Perform in reverse order for assembly.
5. Then, install the base.
6. Install dry batteries, clear EPROM, and perform settings and span adjustment in C1, C2, and
C3 modes.
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4.1.3 Load Cell Replacement
1. Remove the load cell cable and ground cable by using the soldering iron.
2. Remove the ST4×10 screw which fixes the cable clamp.
3. Remove the four M5×16 screws which fixe the plate support at four case locations.
4. Remove the case.
5. Remove the four ST4×14 screws which fix the plate support and platter.
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6. Remove the M6×25 hexagonal bolts, spring washers and flat washers, which fix the plate support and
load cell in two locations both above and under.
7. Fix a new load cell and fix in four locations on the upper and lower plate support with flat washers,
spring washers, and M6×25 hexagonal bolts order.
The direction of load cell installation should be carried out on the lower plate support on the cell cable
side.
8. Confirm whether each cell limit space in the 8-location set screws is within a specified value.
Adjust by turning the set screws to the regulations value, and apply the screw lock agent if differing
from a specified value.
9. Start the test mode, and perform the C3 mode span adjustment.
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4.2 Assembly Procedure (Large Size: 15kg • 30kg)
4.2.1 Base Replacement
The seal restricts the peel according to the country by a no report and doing as wanting
put it.
Do the procedure in a pertinent country.
Disassembly procedure
1. Remove two dry batteries when using the batteries. Remove the AC adaptor when using the
AC adaptor.
2. Remove the four foot levels.
3. Peel off the approval seal.
4. Remove the four M4×10 screws.
5. Lift the base, and pull out the battery harness from CN2 of the main board PS-005.
Assembly procedure
1. Do in the reverse order for assembly.
2. The material of approval seal is void seal. It is not possible to use it again. Put a new approval
seal.
KERN
- 26 - GAB/GAS-SH-e-0711
4.2.2 Board Replacement
1. Remove the load cell cable and ground cable by using the soldering iron.
2. Remove the three ST3×8 screws where the board is fixed.
3. The board is fixed with the four hooks and one lib as shown in the photo.
Press down the place shown by the arrow, while pulling towards yourself, then remove the
hook 1 by sliding the entire board to the left and out.
4. Do in the reverse order for assembly.
5. Then, install the base.
6. Install the two dry batteries, clear EPROM, and perform settings and span adjustment in C1,
C2, and C3 modes.
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4.2.3 Load Cell Replacement
1. Remove the load cell cable using the soldering iron.
2. Remove the M4×10 screw which fixes the cable clamp, then remove the ground cable and
load cell cable.
3. Remove the four ST4×16 screws where the platter and plate support are fixed.
4. Remove the M6×25 hexagonal bolts, spring washers and flat washers, which fix the plate
support and load cell in two locations both above and under.
5. Fix a new load cell and fix in four locations on the upper and lower plate support with flat
washers, spring washers, and M6×25 hexagonal bolts order.
The direction of load cell installation should be carried out on the lower plate support on the
cell cable side.
6. Confirm whether each cell limit space in the 8-location set screws is within a specified value.
Adjust by turning the set screws to the regulations value, and apply the screw lock agent if
differing from a specified value.
- 28 - GAB/GAS-SH-e-0711
7. Start the test mode, and perform the C3 mode span adjustment.
- 29 - GAB/GAS-SH-e-0711
4.3 Troubleshooting
Symptom Cause Measure
1. Trouble of dry battery power
supply system
• Check and replace dry batteries
• Confirmation and exchange of
battery harness
2. AC adaptor trouble • Check output voltage (DC2.4-6.0V)
and replace AC adaptor
1. The display check does not
start when the power switch is
pushed.
3. Main board trouble • Replace the main borad PS-005A.
1. Garbled EPROM data or
initialized state.
• Initialize, perform C1, and C2 and
C3 settings, then push the memory
switch.
2. Power ON → Display check →
"Err1"
2. Main board PS-005A trouble • Replace the main board PS-005A.
3. Power ON → Display check →
"Err2"
1. Outside weight value start
range
• Check if anything is placed on the
platter. If so, remove it.
• Replace the load cell.
• Replace the main board PS-005A.
4. Power ON → Display check →
“0”kg does not appear on the
display.
1. Weight value is unstable. • Check if something comes in contact
with the platter. If so, remove it.
• Check if there is wind or vibration
near the machine. If so, avoid these.
• Replace the main board PS-005A.
• Replace the load cell.
5. Weight varies at four corners. 1. External or load cell trouble • Check if the horizontal state is being
kept.
• Check if there is foreign article
between the platter and the case.
• Check if space of limit adjustment
screw is narrow
• Replace the load cell.
1. Outside of zero-adjustment
or tare subtraction range
• Check that zero-adjustment or tare
subtraction is within the specified
range.
6. The ZERO or TARE key does
not function.
2. Weight value is unstable. • Check if something comes in
contact with the platter. If so,
remove it.
• Check if there is wind or vibration
near the machine. If so, avoid
these.
• Replace the main board PS-005A.
• Replace the load cell.
1. Auto power OFF setting. • Check if the auto power OFF
function works.
• Default is 60 minutes.
7. The power supply cuts when
time passes.
2. Main board PS-005A trouble • Replace the main board PS-005A.
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