service manual for analog controller models
Contents
1. d Check continuity of and to heater H1 and triac Q1 e Try replacing U1 Q1 or see Replacing Main Control Board 2 a Measure for correct line voltage while the bath is heating Unit won t heat to b Check for DC voltage on the heater If more than 30 VDC replace triac Q1 Also check H1 set point heater resistance 3 a Remove U1 IC and test again If still heating replace Q1 If stopped heating Q1 is okay Re insert IC Unit continuously heats b Check all test voltages on the circuit board diagram c Check if Q1 is properly heat sinked with heat sink compound Analog Controller Page 3 4 a Place rear speed switch in HI position Unit should visibly pump the fluid inside of the reservoir Unit does not pump b Check that the pump shaft spins freely and pump impeller s are in place If bearings are worn out replace entire pump motor 5 a Without refrigeration the unit s pumping and stirring will generate heat Check heat rise specification above room ambient Try low pump speed uncovering bath s removing insulation use low viscosity fluid add tap water cooling or a refrigeration unit Unit very slowly rises above the setpoint and won t b On model 911 turn cooling on Set to 20 C To check that refrigeration is working properly come back down feel for warm air exiting out of the rear vent 6 P1 or R6 are not making contact or are defective Controls only near 40 C 7 See Field Calibration Check2. 7 07 1V AG GL Al SONIMS BAVA Schematic Circuit Board Page 7 Analog Controller SLINN AOPZ NI AYO ONY NIR OALNLILSENS HHY SOYAN HAMDd LHM SLINN AOv2 NI OILNLILSENS SOVINT uYMDd MIE NOILVHNIIJNOI HLIM AHVA SOYO ANIN HAMOd S7300W AOv2 NI O3SN SI 299 ST13Q0W NI 0850 ANNO SI TAO EG ANY TLZ S13G0N JILVWSHOS T1VIIHLIITI tee ee nn t 1 1 HOLVOTONI Lv3aH tH 6H BH 2001 lt od 104135 HOLVOTONI 3003 8018111350 MHT 6902 206 208 E802 062 8902 8502 6808 Broz DLF 15028 oroz 022 I Eroa 2E02 ase 5 oases 9 02 5202 dnd 02 2702 ETOZ 2002 8002 5561 TMS 12 1 12 Bret 20 Tagon Xg oak 15 1 aN erd SWHO SWH HOSNaS Decree ee es oi 3 x189 JUNLVYEIGWAL LVLSOHBIHL OLE ALBAVS 2 5 Aor2 289 SNI 7000 LHM NIE LHM Schematic and Wiring Diagram Electrical
3. Analog Controller Page 1 SERVICE MANUAL FOR ANALOG CONTROLLER MODELS Information is reserved for trained qualified technical personnel It includes schematics amp wiring diagrams Any repair or service to a unit is to be performed by a certified technician ONLY Attempting repairs outlined in this guide may result in voiding your warranty THE UNIT BEFORE SERVICING Models 611 71 911 TABLE OF CONTENTS Section 1 Troubleshooting Procedure Section 2 Field Calibration Check Section 3 Testing Temperature Probe Section 4 Replacing Control Board Section 5 Spare Parts List Section 6 Schematics amp Wiring Diagram Analog Controller Page 2 SECTION 1 TROUBLESHOOTING PROCEDURE Note If the unit seems to function normally but fails to control or hold temperature steady first perform instructions as in Conditions and Steps before Troubleshooting the Unit CONDITIONS AND STEPS BEFORE TROUBLESHOOTING THE UNIT 1 Set the HI LO pump speed switch on the rear panel to HI 2 Set up unit a For a closed loop application on the model 911 circulator connect a 1 4 inch diameter or greater hose a few feet long in length to the Inlet and then Outlet b For the model 71 immersion circulator clamp to the side of a bath container 3 Use the same fluid and the same setpoint temperature as your application Always use enough fluid to cover pump housing and heater 4 Unit should visibly pump the fluid inside the r
4. H 7 11 16 INCHES FROM 215 238 MOUNTING SURFACE PCB1 71 911 PC BOARD ASM WITH RTD PROBE TESTED 120V 500 107 1 71 911 PC BOARD ASM WITH RTD PROBE TESTED 240V 500 108 H1 HEATER TUBULAR 3 1 2 O D COIL 1KW 120V 215 067 H1 HEATER TUBULAR 3 1 2 O D COIL 1KW 240V 215 068 NE1 NE2 LAMP NEON GREEN RIGHT ANGLE 120V 215 161 NE1 NE2 LAMP NEON GREEN RIGHT ANGLE 240V 215 139 M2 FAN FOR REFRIGERATION AXIAL 4 INCH DIAMETER 120V 215 296 M2 FAN FOR REFRIGERATION AXIAL 4 INCH DIAMETER 240V 215 297 Analog Controller Page 5 S1 TEMPERATURE PROBE 7 X 1 4 0 D RTD 1855 ohm 0 C 200 078 CB1 CIRCUIT BREAKER MAGNETIC 1 POLE 12A 120V 215 041 CB2 CIRCUIT BREAKER MAGNETIC 2 POLE 15A 240V 215 157 SW1 SW2 SWITCH GREEN INDICATOR MAIN POWER OR COOLING POWER 235 026 OTP OTP SAFETY HYDRAULIC THERMOSTAT IMMERSION 120V 215 122 OTP OTP SAFETY HYDRAULIC THERMOSTAT IMMERSION 240V 215 167 SW3 SWITCH SLIDE FOR PUMP HIGH LOW SPEED 235 008 Page 6 Analog Controller SECTION 6 SCHEMATICS AND WIRING DIAGRAM WAOVIO 110041 116 IZ 1500 WILNSLOd SOVLIOA LV SI LINDY IMLING ONIYNSVIN NAHM NOTIN JAVIL SJOVLTOA 1531 116 ONY 14 78004 AL NIW AG E 14109135 WIG AG 0782 801 70217201005 ONE ET O VET 6 9 19 IN ASI dW3i HLVB
5. eservoir If not check that the pump shaft spins freely and impeller s are in place If bearings are worn out replace the entire pump motor 5 Check the fluid or fluid mixture a Watery consistancy not thick like maple syrup Viscosity lt 25 centistokes b Not boiling on the surface or freezing at the bottom of the reservoir or to the cooling coils c Not within 5 C of the freezing or boiling point of the fluid 6 On the model 911 if used for an external application a Check the heat load does not exceed the rated cooling power of the refrigeration or the external heat loss does not exceed the heater s 1000 watts Fluids within 40 C of their boiling point can cause so much heat loss as to require more than the 1000 watts of heat provided by the unit especially in containers with a large open surface area Cover uncover and add remove insulation of both the internal reservoir and external application and tubing Insulate the top of the fluid with hollow floating plastic or Teflon balls PROBLEM Corrective Action 1 a Check power supply voltage shown on circuit board diagram If low check R8 and R9 on 240V units for proper resistance If still low or high replace U1 If still low check C1 for Unit does not heat shorted or leaky condition Also check R2 for proper resistance or intermittent heat b Check all test voltages on the circuit board diagram c Check heater H1 resistance 120V 14 40hms Q 240V 580hms Q
6. ng the cover in place Once the cover is loose disconnect the ground wire from the lug terminal Analog Controller Page 4 e Ona sheet of paper note the colors and locations of the wires on the PC Board Or use the wiring diagram on pg 7 e Remove all wires from their terminal connectors on the PC board e Loosen the probe clip from its mounting bracket e Remove the knob insert knob and nut holding the front heater control potentiometer e Remove the three PC board mounting screws e Slide the probe up and away from the probe clip To install the replacement PC board Follow the steps above in reverse order e Slide the probe back into the probe clip e Install the three PC board mounting screws e Install the knob insert knob and nut holding front heater control e Tighten probe clip into its mounting bracket e Attach all wires to terminal connectors according to your diagram e Attach the ground wire to the lug terminal e Attach the cover using two screws e Plug power line into unit SECTION 5 SPARE PARTS LIST REF DESCRIPTION PART Q1 TRIAG ISOLATED TAB TECCOR Q4015L5 15A 400V 200 058 M1 MOTOR PUMP MODEL 911 120V SHAFT LENGTH 6 11 16 INCHES FROM 215 235 MOUNTING SURFACE M1 MOTOR PUMP MODEL 911 240V SHAFT LENGTH 6 11 16 INCHES FROM 215 236 MOUNTING SURFACE M1 MOTOR PUMP MODEL 71 120V SHAFT LENGTH 7 11 16 INCHES FROM 215 237 MOUNTING SURFACE M1 MOTOR PUMP MODEL 71 240V SHAFT LENGT
7. section 2 Setpoint knob inaccurate SECTION 2 FIELD CALIBRATION CHECK There is no calibration adjustment or procedure The setpoint dial accuracy of these units are rated to be within 10 C of NIST actual temperature over the entire temperature range e Check calibration against a NIST traceable thermometer of known accuracy of 1 C or better e sure the setpoint knob is mechanically centered across the dial range e Check all test voltages on the circuit board diagram e Check temperature probe as below SECTION 3 TESTING TEMPERATURE PROBE Remove the probe wires from the board Check that the resistance of the probe is within the tolerance shown on the schematic amp wiring diagram on page 7 If okay then check electrical readings from the probe metal sheath to the two probe leads on the following two items e Check for any resistance reading If there is any the probe is defective e Ona digital voltmeter with an impedance of one megohm or more check for any DC voltage present If there is some the probe is defective SECTION 4 REPLACING MAIN CONTROL BOARD When removing replacing the control board always remove replace the bath temperature probe included with the board Temperature probes are checked at the factory to be within tolerance only when used with that board HOW TO INSTALL A PC BOARD To remove the existing PC board e Unplug the unit from the power line e Remove the two screws holdi
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