TB23 DiagnosticsTroubleshooting
Contents
1. compared with an external calibrated gauge Incorrect calibration Pressure transducer has drifted Calibrate the pressure transducer D Series Manual Section Calibration Pressure drifts out of calibration after it has been calibrated Pressure transducer has failed Pressure reading is grossly inaccurate when compared with an external calibrated gauge does not reflect large changes in pressure and or does not read zero when open to atmosphere Replace the transducer Pump drive board fuses F102 and F104 are open Replace fuses Replace pump drive board and or pressure transducer Controller electronics are damaged Repair replace controller board D Series Manual Section Pump Case Top Removal Test Points Pump does not maintain pressure when ports are closed Leak check failure Seal leakage Replace seals Inspect wear ring and cylinder D Series Manual Sections Seal Cleaning and Replacement Wear Ring Cleaning and Replacement Leakage outside the pump external tubing fittings or valves Repair or replace leaking component Cylinder cap seal Replace cylinder cap seal and tighten cylinder cap D Series Manual Section Calibration Pump sounds like it is running but the piston does not move up the cylinder An overpressure condition has bro ken the shear key Before replacing the shear key ensure that the pumping system is pr2. Diagnostics and Troubleshooting For Teledyne Isco Syringe Pumps Overview If a problem is suspected in the operation or performance of an Isco syringe pump certain procedures are recommended for identifying the problem in the field Steps for verification of pressure and flow rate accuracy and checking for leaks are provided in TBO05 Field Verification Procedures This bulletin explains how to proceed with troubleshooting once a problem has been identified in these and other areas Legacy Pump Controller Lighted display aO TELEDYNE ISCO A Teledyne Technologies Company Syringe Pump Technical Bulletin TB23 Systems using the updated pump controller on sale beginning November 2011 are identified by the lighted display and the blue Dispense DISP button in the fourth row on the control panel The two systems have several differences including maintenance kits see Table 1 below manuals and some procedures DISP button Figure 1 Identifying Legacy Controller and Current D Series Controller Current Pump Controller If troubleshooting identifies a need for servicing or replacement of components refer to the Pump Maintenance and Servicing section of your manual Section 5 of the Legacy manual Section 8 of the current D Series manual Syringe Pump Technical Bulletin TB23 Table 1 Maintenance Kit Contents Piston amp Wiper Seals Wrench Package Cylinder
3. Nebraska 68501 USA Toll free 800 775 2965 Phone 402 464 0231 e Fax 402 465 3001 E mail lscoService teledyne com a TELEDYNE ISCO A Teledyne Technologies Company Teledyne Isco is continually improving its products and reserves the right to change product specifications replacement parts schematics and instructions without notice
4. Cap Seal Various wrenches for use with most common part replacements yl cap seal NOTE Wrench types and sizes may vary between pump Pj models iston seal Wiper Package Numbers If Ordering Separately seal 1000D 60 1247 093 500D 60 1247 068 260D 60 1247 067 100D 60 1247 067 65D 60 1247 130 Control Panel Label Motor Brush Set Depending on use the most frequently pressed keypad buttons may eventu Inspect the top brush which is easier to access ally wear out New brushes are 1 1 cm long Replace both brushes before the top brush wears to a length of 0 4 cm Other option replace entire motor Port Plug k Cable Ties amp Mounts Tubing Connectors Zero Volume Nut amp Ferrule 100D 260D T A Fuses Universal Sensor Harness 100D 260D 500D A tbe Maintenance Kit Part Numbers nstallation Tool Shear ke Ifthe pump motor fails to y Legacy Older Controller D Series Current Controller sopinteewemtotan rear key for 65DM 10000 68 1249 104 1000D 60 1247 060 ea dpi 500D 68 1249 102 500D 60 1247 072 e shear key may require Installation tool Sein 260D 68 1249 101 260D 60 1247 073 100DM DX 68 1249 100 100DM DX 60 1247 074 65D 68 1249 111 65D 60 1247 087 65DM Call Factory 65DM 60 1247 094 Troubleshooting Tables On the following pages Tables 2 through 5 provide basic syringe pump troubleshooting information Under Additional Information are references to relevant sections of the D Series user manu
5. not tight enough A D Converter failure Optical sensor limit sensor failure Damaged pressure transducer POT me Oe Shear key broken indication of failure to auto matically stop in overpressure condition Shear key replacement procedures are available in Section 5 of the legacy manual and Section 8 of the current manual Overpressure Condition If an overpressure condition occurs the pump will stop running It will either stop automatically and display an error message or the shear key will break in which case the motors keeps running but pressure is not developed This can be caused by an electrical problem such as failure of fuse F102 or damage to the pressure transducer It can also occur if the cylinder has been screwed too tightly into the mounting block The cylinder should be screwed in by hand until it bottoms out against the stop ring in the cylinder mount When it stops back it off until the transducer cable is pointing straight back Use the wrenches and cylinder clamp from the maintenance kit to hold the cylinder in place while screwing the cap onto the cylinder Unstable Pressure Densification inside the tubing associated with high viscosity applications can cause clogs Ensure that temperature and other factors affecting viscosity are carefully maintained For solutions refer to TB17 High Temperature and High Accuracy Options Fluid Leakage Although slight leakage during normal operation is expec
6. 02 Cylinder Connection Package Temperature and Pressure Con trols Technical bulletin TB08 CO Appli cations and Tech Notes For additional support contact a Teledyne Isco Applications Spe cialist Pump cannot be set to desired pressure Factory specified maximum pressure exceeded or user set pressure limit exceeded Set pump to a lower pressure Universal sensor harness limit sensor failure Pump will not run orei Pump B or C not connected to AC Power No error message Software has been updated without a controller reset Verify operation of the limit sensors 2 total Connect AC Mains Power to the pump Perform a controller reset Refer to Technical bulletin TB09 Flash Memory Upgrade D Series Manual Section Motor Control Limits Pump cable not attached Pump module not powered on 5VDC unavailable Controller will not power up Verify 5VDC on controller board and on power drive CBA Calibration Legacy controller only or fuse replacement may be necessary D Series Manual Section Test Points Syringe Pump Technical Bulletin TB23 Table 3 Displayed Messages The pump speed does not correctly correspond with the amount of power required to run the motor Worn motor brushes brushes Additional Symptom Cause Solution Information D Series Manual Section Temporary software hangup Hard system reset Resetting the System Tachometer sensor f
7. ailure A to D converter fail ure Verify by using a different controller Replace or align the tach sensor Older pumps may have a bad tachometer sensor or alignment FAILURE POSITION A B C Replace entire motor or just the D Series Manual Section Motor Brushes Fuse 101 blown Replace F101 Universal sensor harness limit sensor failure Verify operation of the limit sen sors 2 total Replace harness if either sensor fails D Series Manual Section MOTOR CONTROL LIMITS Cylinder screwed too tightly into the mounting block Using the cylinder wrench see Table 1 to back the cylinder off and tighten it properly Refer to technical bulletin TB22 Care and Maintenance Failed drive transistor on motor drive board Replace motor drive board FAILURE PRESSURE A B C A B C OVER PRESSURE Pressure has exceeded maximum range of the pump Constant Flow Mode models 260D 500D amp 1000D Pressure has exceeded that specified in the graphs shown in Section 1 of the user manual Set pump to a lower pressure Pump will not run CYLINDER EMPTY message displayed Pump empty Piston at top of cylinder Refill the pump Pump will not refill CYLINDER FULL message displayed Pump full Piston at bottom of cylinder Run the pump CYLINDER EMPTY message displayed but piston is not at top of cylinder cylinder not really empty CYLINDER FULL message displayed but pisto
8. al included with your pump as well as online documents containing detailed instructions for the solutions outlined in the tables Many test procedures and repairs listed here require accessing the interior of the controller or pump module Instructions for doing so are provided in the section following the tables Table 2 General Troubleshooting Syringe Pump Technical Bulletin TB23 Symptom Cause Solution Additional Information Fluid leaking from drip pan Fluid leaking onto the worm gear Damaged pump seals Replace pump seals Fluid leaking from where the cylinder cap meets the cyl inder Failed cylinder cap seal Replace cylinder cap seal See sections on Fluid Leakage later in this bulletin D Series Manual Sections Seal Cleaning and Replacement Wear Ring Cleaning and Replace ment Shear key broken worm gear is turning but ball screw is not Replace shear key D Series Manual Section Overpressure Conditions Gross leak Pump has no restriction Tighten fittings Clean or replace piston seal Add restriction pressure downstream D Series Manual Sections Seal Cleaning and Replacement Back Pressure Regulation Pump runs never reaches set pressure Pumping Gas Isco pumps are designed for pumping liquids and supercritical fluids If pumping CO use a dip tube and take necessary measures to ensure that the CO remains in a liquid state D Series Manual Sections C
9. as there are no scratches or marks on the sealing surface Valves e Pumping caustic substances or fluids containing particulates can shorten the life of valve packages usually causing leakage to occur Options are available from Teledyne Isco for reducing or preventing damage of this nature These options are discussed in TB04 Pumping Salt Solutions and Brines and in the Custom Pumps Brochure e Leakage may be accompanied by a VALVE ERROR message Cycle power and see if the message reappears If it does repair or replace the valve package Valves may not be closing properly For exam ple if the inlet valve opens but the outlet does not fully close a vacuum can be created The valve seals may become worn or a valve may be impaired by thickening of viscous flu ids In electric valves it is also possible for a motor to fail Failure of electric valves may be further indi cated by leakage from the small opening in the side of the valve body see Figure 4 close up Figure 4 Weep hole on electric valves Air valve packages can often be restored Seal kits are available for this type of valve Kits available 1000D 60 5364 168 500D 260D 100DM DX 60 5364 071 65D 60 5364 299 Electric valves or motors can be replaced Replacement motors require current adjustment before operation can resume Refer to the D Series user manual section Electric Valve Motor Calibration Teledyne Isco Inc P 0 Box 82531 Lincoln
10. ing and Replacement Technical Bulletin TB05 Field Verification Total volume collected lt calculated AND pressure lt 500psi Standard seals are generally more effective at pressures gt 500psi Add backpressure resistance Use low pressure seals Technical Bulletin TB10 Low Flow Operation Contact Teledyne Isco s application special ists for further assistance 402 465 2086 or 800 775 2965 Total volume collected lt calculated but still within specified leak rate equipment precautions Low flow applications often require special laboratory and D Series Manual Section Section 1 2 Specification Tables Technical Bulletin TB10 Low Flow Operation Contact Teledyne Isco s application special ists for further assistance 800 775 2965 Regulation Although minute fluctuations within the uL range at set pressure are considered normal low flows in particular can benefit from smaller cylinder capacities back pressure regulation control of the ambient and fluid temperatures For details refer to TB10 Low Flow Operation and TB07 Temperature Control Jacket Setup and D Series Manual Section Back Pressure a For valve leakage see the procedure Valves on page 7 Instructions for calibrating new electric valve motors is provided in the D Series user manual Table 5 Pressure Troubleshooting Symptom Cause Solution Additional Information Pressure reading is somewhat inaccurate when
11. n is not at bottom of cylinder cylinder not really full Universal sensor harness limit sensor failure Verify operation of the limit sen sors 2 total Replace harness if either sensor fails D Series Manual Section MOTOR CONTROL LIMITS VALVE ERROR Cycle power If the message reappears repair or replace the valve package Electric Valves Valve or valve motor failure repair kits available Air Valves May be restorable w new seal kit D Series Manual Section Flectric Valve Motor Calibra tion Error messages can only be removed by correcting the problem and restarting the controller If diagnostics indicate CBA component failure other than fuses replace the CBA Table 4 Flow Rate Troubleshooting Syringe Pump Technical Bulletin TB23 calculated AND e Pressure gt 500psi is out of specified leak rate e Flow rate gt 0 25ml min e Calculated Volume Collected Volume Collection Time cylinder Problem Cause Solution Additional Information D Series Manual Sections Seal leak Replace seals Inspect wear ring and Section 1 2 Specification Tables Total volume collected lt eal leakage Seal Cleaning and Replacement Wear Ring Cleaning and Replacement tubing fittings or valves Leakage outside pump External Repair or replace leaking component Cylinder cap seal Replace seal and tighten cylinder cap D Series Manual Section Seal Clean
12. operly installed and programmed D Series Manual Section Overpressure Conditions a See Incorrect or Unstable Pressure Readi ng on page 6 for additional troubleshooting information Syringe Pump Technical Bulletin TB23 Accessing Internal Components The following information applies across many troubleshooting areas Refer back to this section when investigating more specific issues DANGER Risk of electric shock Disconnect the electric power before servicing Only trained service personnel may remove the case top Controller Case Top Removal Troubleshooting for a number of issues can be done on the controller main circuit board Remove the four screws holding the case top in place two screws on each side Lift the cover straight up and off f C Q x 4 a1aa Figure 2 Controller case top screws 2 of 4 shown Pump Case Top Removal Some maintenance and troubleshooting procedures require accessing the pump module interior Remove the four screws holding the case top in place two screws on each side Lift the cover straight up and off Figure 3 Pump case top screws 2 of 4 shown Incorrect or Unstable Pressure Reading If the pressure is out of specification has a constant reading of Opsi or will not stabilize check the following points Incorrect or Zero Pressure 1 Ensure that fuses F102 and F104 are not blown 2 Cylinder cap screwed on too tight or
13. ted leakage exceeding specifications refer to TBO5 Field Verification Procedures may signal a problem Areas to check are listed in order of likelihood along with possible causes Damaged seals e Pump seals are a consumable item that becomes worn over time Replace cylinder cap seal piston seal and wiper seal annually Replace more often for applications involving heavy use or harsh abrasive substances Syringe Pump Technical Bulletin TB23 e Dirt or other solids on the seal can cause leakage If removed and rinsed with distilled water a seal may still be usable but reused cap seals may leak e The seals are easily damaged Use great care during handling not to leave debris or fingernail imprints on the seal s surface e Ifthe cylinder cap is not screwed on tight enough the cap seal may not be able to prevent leaks Fittings e Problems with the fittings can cause leakage e Inspect all plugs ferrules and tubing connections for damaged surfaces and threads e Ensure that all fittings are properly tightened Surface finish e Visually inspect the inside of the cylinder for scratches by shining a flashlight down inside the surface should have a mirror finish Some scratches or score marks may be repaired at the factory If the marks are very deep however the cylinder must be replaced e Ifthe surface of the piston is damaged the piston must be replaced e The piston retainer can function normally as long
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