1. Version 20090811
Part#14137003
OMI+_Maint_EN_20090811.pdf
OMI+
On Machine Inspection
Maintenance Handbook
2. Borgwaldt KC
7741 Whitepine Road Schnackenburgallee 15
Richmond, Virginia 23237 USA D-22525 Hamburg
Tel: +1 (804) 271-6471 (General Inquiries) Tel: +49/40/853138-0
Tel: +1 (804) 743-9790 (Technical Support)
Fax: +1 (804) 275-9070 Fax: +49/40/850 56 00
Email: info@borgwaldt-kc.com Email: BT@borgwaldt.de
Internet: www.borgwaldt-kc.com Internet: www.borgwaldt.de
Safety:
Before installing, operating or maintaining this instrument, you must read the enclosed Handbooks.
Refer to this Handbook for further information regarding the indicated
hazard.
Equipment covers should not be removed until all power is turned off
and disconnected. Access to internal components should be
performed by a trained technician.
Handbooks may be provided printed, or electronically on CD, for your convenience.
Copyright:
The contents of any BKC Manuals are expressly for the use of our customers. Any reproduction or
distribution with the written permission of Borgwaldt KC is prohibited.
All rights reserved.
Handbook Images:
• Photos or graphic images are listed in the Table of Figures. References to these images,
contained in the Handbook’s text, are in [brackets] format.
OMI+_Maint_EN_20090811 OMI+ page 2
3. Table of Contents
Table of Figures ....................................................................................................................... 4
Safety...................................................................................................................................... 5
General Safety Information .................................................................................................... 5
Definition of Terms and Symbols ............................................................................................ 6
Guarantee................................................................................................................................ 7
Main Areas............................................................................................................................... 8
Maintenance Schedule and Cleaning........................................................................................... 9
Summary Overview ............................................................................................................... 9
Daily .................................................................................................................................. 10
Hopper Cleaning: ............................................................................................................. 10
Weight Unit Cleaning........................................................................................................ 11
Size Unit Cleaning ............................................................................................................ 12
PDV Unit Cleaning ............................................................................................................ 13
Weekly ............................................................................................................................... 14
PDV Sleeves Replacement................................................................................................. 14
Sensor Cleaning ............................................................................................................... 18
Monthly .............................................................................................................................. 19
PDV Filter Maintenance..................................................................................................... 19
PC Filter Cleaning............................................................................................................. 21
Annually ............................................................................................................................. 22
Size Unit Drive Belt Replacement....................................................................................... 22
PDV Air Filter Replacement ............................................................................................... 23
PDV O-rings..................................................................................................................... 24
PDV Unit Hose Replacement ............................................................................................. 24
PC Cleaning ..................................................................................................................... 25
Air System Maintenance ................................................................................................... 27
Exterior Case Maintenance................................................................................................ 28
Maintenance Parts .................................................................................................................. 29
OMI+_Maint_EN_20090811 OMI+ page 3
5. Safety
General Safety Information
WARNING !
The operating safety of the instrument should be considered critical for every user. The instrument
should only be used as intended and described in this Manual.
CAUTION !
Before starting up and operating the unit, the operating personnel must receive instruction in the
correct use of the unit. Personnel must be made aware of the risks associated with operating the
unit. Personnel must be familiar with the warning symbols.
The instrument may be operated only by trained and experienced personnel. If a certain task
requires more extensive qualifications, it will be indicated in the appropriate section of this Manual.
It is our intention to offer you safe, state-of-the-art products now and in the future. Please help us
achieve this goal. Please inform us of any of the following:
• Interruptions/faults in unit operation
• Defective or malfunctioning parts
• Problems when operating or handling the machine
OMI+_Maint_EN_20090811 OMI+ page 5
6. Safety
Definition of Terms and Symbols
This section explains the terms and symbols referring to safety that appear in these operating
instructions or on the unit and packaging.
The following terms and symbols are used on the Packaging, Equipment, or in this Handbook:
Indicates imminent, potential risks or hazards. Failure to comply
DANGER ! with the stated instructions can result in death or serious injury.
This term always appears with a warning symbol.
When this symbol is present in a dialog box, as illustrated,
disconnect electrical power before opening the enclosure. This
CAUTION !
procedure, if performed incorrectly, or in not performed by a
properly trained technician, may result in electric shock.
When this text is present in a dialog box, as illustrated, special care
must be taken when performing these instructions. This procedure,
WARNING !
if performed incorrectly, or if not performed by a properly trained
technician, may result in equipment damage.
When this text is present in a dialog box, as illustrated, special care
must be taken when performing these instructions. This procedure,
NOTE ! if performed incorrectly, or if not performed by a properly trained
technician, may result in the operation of the equipment being
compromised.
Safety Symbols
OMI+_Maint_EN_20090811 OMI+ page 6
7. Guarantee
Borgwaldt KC provides a 12 month warranty on all instrumentation from time of dispatch unless
otherwise stated.
Any technical changes or repairs performed without Borgwaldt KC’s consent during the guarantee
period releases us from our obligations stated in the guarantee.
If you should have any question regarding maintenance and/or the correction of any problems,
please contact Borgwaldt KC.
To maintain the Warranty Guarantee, the Instrument must only:
1. Be installed as described in the Installation Handbook.
2. Be operated as described in the User Handbook.
3. Be maintained as described in the Maintenance Handbook.
4. Be repaired by a BKC authorized technician.
5. Be maintained with BKC original parts.
OMI+_Maint_EN_20090811 OMI+ page 7
8. Main Areas
Touch Screen Hopper
Display
Weight Unit
Size Unit
Pressure Drop
/Ventilation
Unit
Computer
Mounting Stand
Collection Bin
Floor Bracket
MainAreas 01a
OMI+_Maint_EN_20090811 OMI+ page 8
9. Maintenance Schedule and Cleaning
Summary Overview
This Handbook contains detailed instructions for performing the following tasks.
Daily
• Hopper Cleaning
• Weight Unit Cleaning
• Size Unit Cleaning
• PDV Unit Cleaning
Weekly
• PDV Unit Sleeves Replacement
• Sensor Cleaning
Monthly
• PDV Filter Maintenance
• Vacuum Computer (PC) Filters
Annual
• Size Unit Drive Belt Replacement
• PDV Unit Air Filter Maintenance
• PDV Unit Vent or PD Head O-Rings Maintenance
• PDV Hose Replacement
• PC Cleaning
• Air System Maintenance
• Exterior Case Maintenance
OMI+_Maint_EN_20090811 OMI+ page 9
10. Daily
Ensure that Power is
disconnected from the OMI.
NOTE: Compressed Air should not be used to clean the instrument.
NOTE: Removal of tobacco dust should be achieved using a vacuum source to pick up the dust
particles.
Hopper Cleaning: Top Cover
Touch
Screen
1. Lift the Top Cover and slide-up the Front
Plate to remove. [HopperAreas 01]
Drum
2. Clean the path where product samples
travel through the Hopper, using vacuum
[HopperAreas 01]
Front
Plate
HopperAreas 01
OMI+_Maint_EN_20090811 OMI+ page 10
11. (Daily continued)
Weight Unit Cleaning Weight Unit
1. Lift the Release Knob, and slide-open the
Weight Drawer. [WeightUnit 01]
2. Clean the Weight Drawer and
components using vacuum. Note- Use
only vacuum to clean the Rod Weight
Scale area. [WeightUnit 02]
Release Knob Sample Holder
WeightUnit 01
3. The Rod Weight Scale should be NOTE: Special care should be taken not to
carefully vacuumed free of loose sweep dust particles into the top of the Weight
tobacco and dust. Be sure that the Cell cover.
Sample Holder is protected from shocks,
as shocks can damage the balance. Weight Scale
[WeightUnit 02].
Entry Funnel Sample Holder
WeightUnit 02
OMI+_Maint_EN_20090811 OMI+ page 11
12. (Daily continued)
Please ensure that you comply
with all safety measures
required to work with this
equipment.
Size Unit Cleaning
1. The Size Unit drawer is located near the Size Unit
middle area of the OMI+. [MainAreas 10]
MainAreas 10
2. Lift the Release Knob [SizeUnit 01a], and
slide-open the Size Unit Drawer. [SizeUnit
01a]
3. Clean loose tobacco and dust from the Release Knob Drawer
Size Unit. Clean the Size Unit and
components using vacuum pressure air. SizeUnit 01a
OMI+_Maint_EN_20090811 OMI+ page 12
13. (Daily continued)
CAUTION! Special care must be
taken when performing
these instructions. This
procedure, performed
incorrectly, or not
performed by a properly
trained technician, may
result in equipment
damage.
PDV Unit Cleaning
1. Lift the Release Knob, and slide-open the
PDV Unit Drawer. [PDV Unit 01]
2. Clean the PDV Unit and components
using vacuum.
Release Knob Measuring Head Assembly
PDV Unit 01
OMI+_Maint_EN_20090811 OMI+ page 13
14. Weekly
Ensure that Power is
disconnected from the OMI.
PDV Sleeves Replacement
1. Unscrew the top of the Measuring Head top of Measuring Head Assembly
Assembly, by rotating it in a
counterclockwise direction. [PDVunit 01]
2. After the top has been unscrewed, gently PDVunit 01
pull-out the top and interior areas of the
Measuring Head Assembly [PDVunit 02].
PDVunit 02
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15. (Weekly continued)
3. Unscrew the Lower Inner Head Assembly Measuring Head Tip and Paper Ventilation
from the Top of the Measuring Head and Paper Drop Assembly
Assembly. [PDVunit 04]
Lower Inner Head Assembly
PDVunit 04
4. Push the Extraction Tool into the O-Ring
Assembly to remove the inner portion of
the O-Ring Assembly. [PDVtools 02b]
• Special care should be taken to keep
the Tool and Bobbin parallel to the Extraction Tool
Head Body. [PVTtools 02b]
PDVtools 02b
Filter Bobbin Assembly Sleeve
5. Replace all PDV sleeves once a week.
[Sleeves 01], [Sleeves 02b], and [Sleeves
02c] Sleeves 01
Cigarette Bobbin Assembly Sleeves
Sleeves 02b
Sleeves 02c
OMI+_Maint_EN_20090811 OMI+ page 15
16. (Weekly continued)
• Ensure that the new Sleeves are Correct
correctly aligned and centered. • Good circle
[SleevesRightWrong 03] • In center
Incorrect
• Bad circle
• Off center
Incorrect
• Good circle
• Off center
Incorrect
• Bad circle (twisted)
• In center
6. Clean any buildup of dirt that could
prevent the Sleeves from sealing around
the rod.
SleeveRightWrong 03
OMI+_Maint_EN_20090811 OMI+ page 16
18. (Weekly continued)
Sensor Cleaning
1. Clean all sensors, using optical grade
cleaning materials (e.g. “Lens Wipes”) to
clean the surfaces of the Sensors.
[Sensors 01]
Note: In the photo below, enlarged views of the
sesnors are shown with location arrows.
[Sensors 01]
Sensors 01
OMI+_Maint_EN_20090811 OMI+ page 18
19. Monthly
PDV Filter Maintenance
1. The Cambridge fiberglass filter should be
replaced in the PDV Certified Flow Orifice
on a semi-annual basis.
2. The tools required for this maintenance
are: [PDV tools 03]
• A 13mm wrench
• A Filter Housing Removal Wrench
(supplied in the OMI+ Calibration
Test Piece kit) PDV tools 03
Air Fitting
3. Using a 13mm wrench, remove the air
line fitting on the top of the filter housing
(located on the front of the PVE drawer.
[PDV CambFilter 01]
Important: Please ensure that the air hose
is not twist-damaged during removal or
twisted after replacement.
PDV CambFilter 01
OMI+_Maint_EN_20090811 OMI+ page 19
20. (Monthly Maintenance continued)
4. Unscrew the clear plastic filter housing
(use Housing Removal Wrench) [PDV Housing Removal Wrench
CambFilter 02].
5. Vacuum the dust particles from the
Cambridge filter and then carefully
remove the O-ring and filter. [PDV
CambFilter 03] PDV CambFilter 02
6. DO NOT allow dust or dirt particles to fall Cambridge Filter O-ring
into filter housing (The Certified Flow
Orifice is directly behind it).
7. Vacuum and clean the filter housing.
Replace the Cambridge Filter.
8. Clean or replace the O-Ring, re-install the
top filter housing and air fittings.
PDV CambFilter 03
9. Check the manifold Block and clear Manifold Plug
tubing for any signs of debris, if debris is
present then remove, this can be done
by removing the plug [Manifold and Plug
03a] on the right hand side of the
manifold block. Tubing can be cleaned by
removing the tube and blowing through
with an air gun, please ensure both ends
of the tube are disconnected from the
Right Side of OMI+
unit.
Manifold and Plug 03a
OMI+_Maint_EN_20090811 OMI+ page 20
21. PC Filter Cleaning Filters
1. Using Vacuum, clean the two Fan Filters
on the Rear of the Computer Unit.
[ComputerPCB 03]
ComputerPCB 03
OMI+_Maint_EN_20090811 OMI+ page 21
22. Annually
Ensure that Power and Air are
disconnected from the OMI.
Size Unit Drive Belt Replacement
1. Replace the Drive Belt used to rotate the
rod [SizeDriveBelt 01]. Drive Belt 10032093
• Check the bearings and pulleys
that track the belt for smooth
operation.
• Move the Release Mechanism as
shown in [SizeDriveBelt 01].
• The belt can now be removed.
• Replace with the Borgwaldt-KC
replacement.
Press Release Mechanism in this direction
SizeDriveBelt 01
OMI+_Maint_EN_20090811 OMI+ page 22
23. (Annual Maintenance continued)
PDV Air Filter Replacement
1. The air filter [PDV Filter 02] in the OMI-
PDV needs to be checked by a properly
trained technician, and cleaned if
necessary.
2. Replace the PDV filter [PDV Filter 02] Cover
Annually (located in rear section of PDV
drawer). To gain access to the filter, turn
the Filter Cover counterclockwise. [PDV
Filter 01] Among the possible symptoms
of a dirty air filter are:
• erratic readings
• the need to re-calibrate too PDV Filter 01
frequently Replace filter
PDV Filter 02
OMI+_Maint_EN_20090811 OMI+ page 23
24. (Annual Maintenance continued)
Measuring Head Assemblies
PDV O-rings
1. Replace the Measuring Head (Vent or Measuring Head
PD) O-rings. [O-Rings 03] Filter Rod Bobbin Assy.
O-Rings face left
O-Rings
O-Rings face right
Measuring Head
Cigarette Bobbin Assemblies
0-Rings 03
PDV Unit Hose Replacement Rotating Hoses
1. Replace the four PDV rotating hoses.
[HeadHoses 01]
• The hose connections are hand-
tightened. If they have been over-
tightened, use small pliers to loosen.
• Three of the hoses connect to the
Manifold Block at the front of the PDV
unit.
• The other two hoses connect to two
valves behind the PDV Plate.
PDV Plate Manifold Block
PDV Hoses 01
OMI+_Maint_EN_20090811 OMI+ page 24
25. (Annual Maintenance continued)
PC Cleaning
1. It is recommended that the PC hard drive Rear View
should be backed up at least annually. Filter Computer PCB Backplate Filter
2. Remove 4 screws on PC shelf as marked
on photo. [ComputerPCB 03]
3. After removing screws, using handle,
gently pull out the PC shelf to reveal the
internals. [ComputerPCB 03]
4. Photo shows layout of PC and all Securing Screws
connections [ComputerPCB 01]
ComputerPCB 03
5. Vacuum the PC of all dust and debris.
[ComputerPCB 01]
ComputerPCB 01
Filters
6. Replace the two PC Inlet Filters on the
rear of the Computer Unit.
[BottomRearView 01]
BottomRearView 01
OMI+_Maint_EN_20090811 OMI+ page 25
26. (Annual Maintenance continued)
7. Replace the one PC Outlet Filter on the
bottom of the Computer Unit.
[CaseBottom 01].
View of Bottom of PC Case Filter
8. When completed, push in the PC shelf
and replace the securing screws.
CaseBottom 01
OMI+_Maint_EN_20090811 OMI+ page 26
27. (Annual Maintenance continued)
Rear View
Air System Maintenance Regulator
1. Locate the filter assemblies at the bottom-
rear of the OMI+. [BottomRearView 01]
Drain Filter Super Mist Separator Filter
BottomViewRear 01
Twist to separate
Filter (99008197)
• Twist to separate the outside Cover sections of Cover
sections of the Mist Separator Micro
Filter. [MistMicroFilter 01]
• Unscrew to remove the old filter, and
replace the filter. [MistMicroFilter 01] Cover
MistMicroFilter 01
• Twist to separate the Cover sections of
the Air Filter Assembly.
• Replace the filter.
Twist to separate
sections of cover Filter 99008195
AirFilter 01
OMI+_Maint_EN_20090811 OMI+ page 27
28. (Annual Maintenance continued)
Exterior Case Maintenance
1. Vacuum the Upper and Lower Filters in
the Rear Door of the OMI+. [RearDoor
01]
RearDoor 01
OMI+_Maint_EN_20090811 OMI+ page 28
29. Maintenance Parts
List of Maintenance parts for OMI+ and where used in this Handbook.
• 10032093 Drive Belt for Size Module, used on Size Unit page 23
• 14032087 Filter, Dust OMI+ Rear Door Top page 26
• 14032088 Filter, Dust OMI+ Rear Door Bottom page 26
• 14132100 Filter material for Fan 90mm page 26
• 14132107 Filter material for Fan 40mm page 26
• 99003199 PVE Air Filter page 21
• 14134003 Pneumatic: Element, Super Mist Separator Assembly page 25
• 14034004 Pneumatic: Element, Air Filter page 25
• 99003170 3/8” Rotating Hoses (uncut) Page 22
Note: A PDV Maintenance Kit (99009032) is available from Borgwaldt KC, that includes items
needed for Preventive Maintenance. This kit contains hoses that are cut to length.
OMI+_Maint_EN_20090811 OMI+ page 29
![Borgwaldt KC
7741 Whitepine Road Schnackenburgallee 15
Richmond, Virginia 23237 USA D-22525 Hamburg
Tel: +1 (804) 271-6471 (General Inquiries) Tel: +49/40/853138-0
Tel: +1 (804) 743-9790 (Technical Support)
Fax: +1 (804) 275-9070 Fax: +49/40/850 56 00
Email: info@borgwaldt-kc.com Email: BT@borgwaldt.de
Internet: www.borgwaldt-kc.com Internet: www.borgwaldt.de
Safety:
Before installing, operating or maintaining this instrument, you must read the enclosed Handbooks.
Refer to this Handbook for further information regarding the indicated
hazard.
Equipment covers should not be removed until all power is turned off
and disconnected. Access to internal components should be
performed by a trained technician.
Handbooks may be provided printed, or electronically on CD, for your convenience.
Copyright:
The contents of any BKC Manuals are expressly for the use of our customers. Any reproduction or
distribution with the written permission of Borgwaldt KC is prohibited.
All rights reserved.
Handbook Images:
• Photos or graphic images are listed in the Table of Figures. References to these images,
contained in the Handbook’s text, are in [brackets] format.
OMI+_Maint_EN_20090811 OMI+ page 2](data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7)