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5800 Refrigerated Sampler Service Manual

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2. S EN if i r cB 1010 sc a PUMP SENSOR 43 Bees eel y o S d wN 12 A J ew IT CPU P9 1 4 WEE PU P1 300 Litti Om 3 5 j PF 8LK 0 e o o o YELA wo PS2 WI6 O gt zs F PF RED ooo p a L eo kins z COLOR CODES r U 4 Paks PU P 2 O PIO y Y NUMBER Omri Y O O uF O 9 y CPU j q TE i J M2 E 5 T Y PUMP MOTOR e T g J E IR f COMPARTMENT AIR i qe a F E TEMPERATURE SENSOR a KR l dee E D e 7 IOLET c mo 7 E 8 GRAY uN Ss E E 9 HITE ALK 7 pami E EVAPORATOR He ea J 0 gt Ss 5 TEMPERATURE SENSOR O E ot H e oe Lg P3 104 C82 P3 3 4 T EN y El s amp 5 f MAG Tt MAGNETIC SENSOR joo Paid o o CB2 P8 212 7 A A j ALK o o PF WaT EL 5 JO CNI PIEZO FILM ES aA he 130 JO H ct auto Mo aia IO O i INTERFACE COMM RED 2 Ly eA Her a ae 230 VOLT sa ge olay le AI M A LV VUL DISTRIBUTOR SENSOR 7 oe 580 P L E R M az W7ERIBBED CABLE AND WIRING D STEPPER MOTOR Gao NOTES p L Toy AN st 694704058 CABLE 8 WIRE DIAGRAM FRAME ASSEMBLY lee eae o ST o i o e te Kl
3. 5800 Refrigerated Sampler Electrical Wiring OPTIONAL PARTS
4. NOTE For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 27 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List PUMP COVER EXPLODED VIEW Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List 605802010 REPLACEMENT PARTS LIST SHEET 28 OF 30 TELEDYNE ISCO REV D DATE PART NUMBE DESCRIPTION 23161162 SCREW SELF TAP 14 X LONG SST 109080002 RAW LATCH CENTER SERIES SST 231014514 SCREW MACHINE 8 32 X 7 8 PAN HEAD SST 232420832 UT LOCK 8 32 NYLON INSERT SST 2123092 REFRIGERATOR NAMEPLATE 4103113 PUMP COVER 4103114 COVER HINGE 4103125 LATCH KEEPER 4103126 HINGE P REPLACEMENT PUMP COVER ASSEMBLY INCLUDES ITEMS 21 147 148 149 150 605804133 TiSi 152 153 163 4 154 DOES NOT LUDE ITEMS 15 OR 162 231311206 SCREW SELF TAP 6 18 X 3 8 PAN HEAD SST 00410314 PLATE HEAT SHIELD 605803116 LATCH SPACER NOTE For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 29 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List B
5. A SEE 694704058 CABLE 4 WIRE DIAGRAM PS2 WILG f GREEN YELLOW 7 aa B E59 ic a DETAIL A 0 0 0 TERODND WROD LINE CORD oo BLUE i A E GROUND Do i i POWER SUPPLY ORANGE BLUE i ACK BLACK RED c8 BLACK BLACK SELE gaane i 1 URANG TEE DETAIL A ies y 5 DK a SPOTTED RELAY 4 RUN CAP gt RUN CAP ASSY COMPRESSOR Figure A 2 5800 wiring diagram 115V A 3 5800 Refrigerated Sampler Electrical Wiring IR TEMP 0 CUPT AIR TEMP 3
6. 3 7 Refrigeration Module 0 ccc cette e nee 3 9 3 4 1 Inspection Troubleshooting and Servicing ooooooooo o 3 10 34 2 Inspection cece Bae a eel Die eas eek ee ae hee ed 3 12 3 4 3 Refrigerant Charging 0 eee 3 16 3 4 4 Condenser Fan 0 cece ro 3 17 3 4 5 Module Replacement 0 00 c cece eee nen eens 3 19 Refrigeration Cool Down Test 0 0 ccc cece eee ene nee 3 23 Section 4 CPU and Power Supply 4 1 4 2 4 3 4 4 4 5 5800 CPU Circuit Board Description 0 00 cee eee eens 4 1 AL Processor Ulla a ind Dee Ma ae R eh Os ee es 4 1 4 12 Memory U1L3S 14 aiid Gh asc alee da a Ged dua toate lave aia 4 2 4 1 3 1 0 Ports U26 29 este A ie a shoes hc ages 4 2 4 1 4 Power Supplies U9 27 28 VR1 P10 0 eee 4 2 4 1 5 Serial Port Ult ia 4 2 4 1 6 Flow Meter Interface U25 36 P12 oooooooooooooo o 4 3 4 1 7 Liquid Detector U4 10 P2 0 cee eens 4 3 4 1 8 Temperature Inputs U12 P38 2 eee 4 3 4 1 9 Microprocessor Supervision U18 0 0 cece eens 4 3 4 1 10 Distributor Motor Drive U40 P11 Rotation Sensor P14 U32 4 3 AAAI LCD OTAR 55s 68525 i etek ti ea 4 4 4 1 12 Pump Drive U20 21 22 23 24 25 Q8 Q14 Q16 P8 10 4 4 4 1 13 Case Heater U33 2 ene teen nee 4 4 4 1 14 General Outputs U37 U39 P13 2 ce ene 4 5 4 1 15 Analog Inpu
7. J Figure 3 3 Removing evaporator temp sensor Cut cable ties 3 4 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System 6 Slide the rear wall sensor out of its plastic holder located behind the power supply plate as shown in Figure 3 4 Close up of sensor in holder Figure 3 4 Removing rear wall sensor Power supply plate not shown 3 5 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System 7 The wiring assembly enters the rear of the refrigeration cabinet just above the upper left corner of the fan Unscrew the black cord grip fitting from the bulkhead fit ting in the refrigerator s rear wall 8 Gently loosen the bulkhead fitting with the 16 open end wrench and unscrew it from the refrigerator cabinet Pull the cable connector out through the threaded opening Cord grip fitting Bulk head Q lt fittings SAY SER sensor cable Temp sensor A Cord grip O Ces cable connector fitting 5800 rear wall ae Pre E L zo zt Bulkhead fitting Figure 3 5 Temperature sensor wiring entry at rear of cabinet Installing the new cable 1 Carefully feed the connector end of the new cable through assembly the threaded opening from the rear of the cabinet 2 Apply a coating of the clear silicone sealant such as Dow Corning 7
8. 231611620 EW SELF TAP 14 X LONG SST 9803111 HINGE R 4703010 R GASKET 410402 R LATCH A SSEMBLY LACEMENT 047 UDES IT DOOR ASSEMBLY EMS 18 21 91 54 60 amp 86 1016 ODEL R EFRIGERATION DOOR 05 LATCH ACCESSORY KIT UDES IT EMS 21 amp 60 NOTE kg 2 For current prices and quotations on parts contact Isco Service Department This list is subject to change without notice B 17 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List DETAIL A 15V 8 230V DETAIL B 230V ONLY OG 2X 8 CAUTION When installing replacing the refrigeration unit the line cord E MUST be properly secured Hold the line cord taut to remove any slack and attach a cable tie as shown This is to ensure that the cord cannot be pushed into the enclosure and be caught in the fan Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List 605802010 REPLACEMENT PARTS LIST SHEET 18 OF 30 TELEDYNE ISCO REV D DATE PART NUMBER DESCRIPTION 231310208 SCREW SELF TAP 6 X 1 2 LONG TORX SST 231611620 SCREW SELF TAP 4 X 1 LONG SST 232119000 JAM NUT 378 16 X 56 THICK SST 603113028 C
9. 0 ccc eects 2 12 2 17 Proper installation of pump gasket 0 0 0 ccc eee 2 13 2 18 Improper installation of pump gasket 0 0 cece ees 2 14 2 19 Removing the detector protective barrier 0 c eee eee ee eee 2 15 2 20 Cut a notch in the top cover for the AC line cord to pass through 2 16 2 21 Install heat shield inside cover 0 cece eee ee eee tenes 2 17 2 22 Install heater under PUMP ooo 2 17 2 23 Install line cord clip just inside the notch in the cover 2 18 2 24 Distributor arm A and discharge tube B oo oooooooomoom oo 2 19 2 25 Distributor module removal 0 cece eect e eee 2 20 2 26 Removal of stepper motor and optical sensor e cece eee 2 21 2 27 Distributor assembly exploded view 0 00 cee cece ence eens 2 22 2 28 Distributor gasket replacement 00 e cece eee eee eee 2 23 2 29 Reassembling the distributor shaft 0 0 ccc cee ees 2 24 2 30 Improperly positioned timing belt 0 cece eens 2 24 2 31 Installing the cover plate 0 0 ccc eee ne nns 2 25 2 32 Timing belt alignment 0 0 0 cece cee een eens 2 25 2 33 Installing the optical sensor 20 00 2 26 3 1 Control panel module removal 0 0 0 ccc eee nes 3 3 3 2 Ferrite bead on temperature sensor cable connector end 3 4 3 3 Removing evaporator temp sensor
10. B 41 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List B 42 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List 604702065 REPLACEMENT PARTS LIST SHEET 12 OF 14 TELEDYNE ISCO REV DATE 082107 ITEM PART NUMBER DESCRIPTION 299000702 291001081 RUBBER STOPPER 5 GALLON GLASS BOTTLE WITHOUT STOPPER NOTE For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 43 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List B 44 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List REPLACEMENT PARTS LIST SHEET 14 OF 14 TELEDYNE ISCO REV NO PART NUMBER DESCRIPTION 299001222 BOTTLE CAP 2 002963002 5 GALLON PE BOTTLE 3 609804003 BOTTLE LOCATING BASE NOTE For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 45 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List B 46 5800 Refrigerated Sampler Service Guide Index bottle configurations 1 2 Cc cleaning pump 1 9 refri
11. These are I O expander chips that communicate serially with the CPU over the SPI bus U26 provides 6 outputs that are column drivers for the keypad which is arranged in a 4 by 6 matrix The 4 row signals come back directly to the CPU The keypad is not continuously scanned Normally the column lines are pulled low by the port and the row lines are pulled high by pull up resistors If a switch is pushed one of the row lines goes low The 4 row inputs are programmed in the CPU to generate an interrupt that then scans the columns by taking them low one at a time U29 provides outputs for the distributor motor and refrigeration controls Twelve volt power comes into the board on P10 The current goes through PTC R120 and then to protection in the form of a tran szorb and capacitors The 12 volts goes through a voltage divider R37 40 to an a to d input so the diagnostics can monitor the input voltage The 12 volts is split into 3 paths with various degrees of filtering The lightly filtered 12V goes to the pump drive circuitry beeper and case heater VIN goes to the 5 volt switching regulator Vp with the most filtering goes to the 3 3V regulator and the 5V linear regulator U28 is a switching regulator that operates from Vp The 3 3 volts from this regulator supplies the CPU memory and most of the other ICs 3 3 volts also goes through an LC filter L1 C9 to power the analog 3 3V circuits U27 is another switching regulator that p
12. Tools T 15 torx screwdriver 16 nut driver 1 open end wrench approximate size may vary slightly 4 6 1 Line Cord Removal To access the line cord connections you must first remove the power supply from the sampler Follow the removal instructions in Section 4 5 observing all warnings and cautions 1 Remove the eight self tapping torx screws holding the back cover on the mounting plate and remove the back cover Figure 4 15 A CAUTION Do not remove the Phillips screw in the center of the back cover This is for testing purposes only and must remain in place to keep the unit sealed 4 22 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Torx Screws 8 s Do NOT loosen this screw Figure 4 15 Remove power supply cover 2 Remove the lock nut holding the line cord ground connec tor on the mounting plate Figure 4 16 3 Disconnect the blue wire from W3 on the power board and the brown wire from W4 on the power board Figure 4 16 4 23 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply M Note These two connectors may be difficult to remove Never pull the wires You may need to ease them up from the board with a flat screwdriver Use care not to damage the board Ground wire wires Figure 4 16 Line cord connections 4 Using the open end wrench unscrew the black plastic nut from the line cord bulkhead fitting and pull the old cor
13. and black wires Cable connector Enlarged view of fan power terminals Figure 4 10 Remove fan mounting screws and disconnect cable view from inside refrigerator 9 Inserting the screwdriver through the holes in the heater plate remove the two Phillips screws from the power sup ply back plate and remove the power supply Figure 4 11 4 19 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Figure 4 11 Power supply back plate 4 5 2 Fuse The power supply has a fast blow 4A 250V 5mm x 20mm glass fuse to protect the sampler controller This replaceable fuse is located on the converter board behind the white AC connector you may need to disconnect this connector to access the fuse Fast blow fuse Figure 4 12 Fast blow fuse on the new power supply 4 5 3 Power Supply 1 Mount the replacement power supply with the two large Replacement Phillips screws 2 Reconnect the wires to the compressor and replace its cover A IN CAUTION D Earth ground bonding conductor Ensure that the green yellow wire is reconnected to this terminal 4 20 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 3 Route the line cord through the refrigeration module and secure it in place with the bushing Hold the line cord taut to remove any slack and attach the cable tie as shown in Figure 4 13 Cable Tie Bushing Figure 4 13 Secure AC Power cord
14. ER ee POTTED RELAY amp 7 l RUN CAP ASSY PS2 NV r SMOOTH P52 W601 TERMINAL BOX V F A A e ALA ae com do A 3 ME nd POWER SUPPLY l LINE CORD TERMINAL BOX po pe To GROUND E de a eo ol i EER ORANGE ORANGE GREEN YELLOW 0 OS SEE DETAIL B GROUND WIRE lt co T 4 LY RELAY RUN cap COMPRESSOR Fr Figure A 3 5800 wiring diagram 230V A 4
15. Lift the control panel away from the refrigerator body to expose the wiring connectors 5 Disconnect wiring connectors P1 and P10 6 Place the control panel back on the refrigerator body and 4 16 start at least two screws to temporarily hold the panel until the new harness is in place 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Capacitor and relay Disconnect wires Figure 4 6 Electrical connections on 115V compressor Capacitor and relay Figure 4 7 Electrical connections on 230V compressor Figure 4 8 Control panel removal replacement 4 17 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 7 Unscrew the black cord grip fitting from the bulkhead fit ting in the rear wall above the upper right corner of the fan With 2 Phillips remove the nylon cable clip Pull the control panel power cable out through the threaded open ing M Note Turn the connector sideways to fit through the opening CPU CBA lt power cable cord grip fitting o O O CPU CBA 7 Connectors 5800 Rear Wall Cord Grip Fitting Bulkhead Fitting Figure 4 9 Cord grip fitting on refrigerator wall 4 18 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 8 From the front interior of the refrigerator remove the two Phillips screws holding the fan in place and remove the fan s power cable by disconnecting the red
16. CPU TEST HH MM test This command displays the time and date of the ae CPU test as saved from the T99 command A pais y A time date of 00 00 1 JAN 77 means the thereby serving as verification for the T99 test time date has not been saved 4 4 Control Panel Some issues involving the 5800 control panel may indicate that a software update is required Verify that the sampler has the PSREN latest soft ion bef lacing the control 1 60 5804 152 Chinese atest software version before replacing the control panel 4 4 1 Software Version Select SYSTEM IDS to view the sampler s software version SELECT OPTION lt gt SYSTEM IDs Select the SYSTEM IDs option and press Enter twice HARDWARE ____ SOFTWARE _ _ This screen lists the version numbers of the installed hardware and software Press Enter to return to the SELECT OPTION lt gt screen To update the sampler s software refer to Section 1 5 Software 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 4 4 2 Control Panel Removal A CAUTION Updating the sampler s software affects the program settings and may completely erase the stored data Record program settings and collect all data from the sampler before proceed ing WARNING Always disconnect the 5800 sampler from AC power before performing service and repairs 1 2 3 Open the top cover of the sampler Remove the mounting screws see Figure 4 1
17. Carefully lift the module away from the refrigerator body to expose the wiring connectors Referring to Figure 4 2 on the following page label the wir ing harnesses with the circuit board locations for ease of reconnection to the new panel Disconnect the wiring harnesses from the old panel Figure 4 1 Control panel module removal replacement 4 12 4 4 3 Control Panel Installation Installation Clean the control panel module s mounting surface on the face of the refrigerated compartment This will help ensure that the gasket on the new module will seal the enclosure Ensure that the gasket seal is in place The gasket surface must be smooth clean and free of nicks or cracks If any imperfections are visible replace the gasket Isco part 60 3113 028 1 2 Attach the wiring connectors to the new module Ensuring that no wires are caught between the module and mounting surface align the module over the mounting holes 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 3 Reinstall the control panel screws and tighten down uni formly and snugly 16 to 18 in lbs 4 Reconnect power and perform all diagnostic tests P6 m R133 ro PB mi sey Figure 4 2 Control panel wiring connectors 4 13 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Table 4 3 Control Panel Identification and Wiri
18. E z COMPARTMENT AIR I BROW M2 de z ES Y TEMPERATURE SENSOR 2 EL PUMP MOTOR Rk Pe Lo E Eo YELLOW tc 4 E 2 ER 5 GREEN a o eee Bd PE 6 BLUE ca2 PIOR D a ca Pio to i VIOLET z 8 GRAY dl F 9 WHITE d H A o BLK m F EVAPORATOR 3 E TEMPERATURE SENSOR fe TE L FSI REDZ i g 2 2 3 caz P3 I 4 D 082 P3 304 SI Sin e z Tror 5 5 25 30 MAG Fer MAGNETIC SENSOR NED pa SYN o o CB2 P8 2 2 o 7 o ja CB2 P8 310 P Pa LK JN 3S i J PF a WHT 9 GRN 5 nO CN PIEZO FILM y AAA o 3 r F1 7 INTERFACE COMM ee a IO BLK 0 i Y RED 2 BLU 6 VEL 4 HO RED DISTRIBUTOR SENSOR ola Le Al a W_ MI PS2 W8 SMOOTH STEPPER MOTOR rem 8LK 5800 SAMPLER WIRING DIAGRAM FRAME ASSEMBLY Ti E E i SMOOTH PS2 WSU NOTES
19. LONG SST 4103046 LATCH KEEPER 4103107 CLIP FLIP COVER WITH LOCKING HASP CONT PANEL FASTENER ACCESSORY KIT ES ITEM 142 C LATCH KEEPER ACCESSORY KIT INCLUDES IT L C 4109003 Al FS ITEMS 21 8 49 D REPLACEMENT FLIP COVER ASSEMBLY D U BU96040C0 Y INCLUDES ITEMS 129 130 131 amp 132 23211900 JAM NUT 5 16 18 1 2 HEX X 3 16 THICK SST 23321320 WASHER LOCK 45 16 INTERNAL TOOTH SST 604703104 SPACER HINGE 604703105 PIN HINGE 605804031 REPLACEMENT CONTROL PANEL ASSEMBLY 231518522 SCREW TRUSS HEAD 8 32 X 1 25 LONG SST 605804152 REPLACEMENT CONTROL PANEL CHINA NOTE For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 7 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List CONTROL PANEL EXPLODED VIEW CONTROL PANEL ASSEMBLY WITH LABEL AND CBA B 8 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List 605802010 REPLACEMENT PARTS LIST SHEET 8 OF 30 TELEDYNE ISCO REV D DATE PART NUMBER DESCRIPTION 231310208 SCREW SELF TAP 6 X 1 2 LONG TORX SST 603113028 CASE BOTTOM BAND GASKET REPLACENENT CONTR
20. This section details the replacement steps for pump components Table 2 1 contains a list of the pump s components with part Table 2 1 Pump Parts List Part Number Thumb screw 60 4704 055 O ring 202 5000 07 Gasket Pump shaft assembly 60 3113 029 60 4708 002 Idler gear 60 4708 017 Motor plate 60 4708 018 Motor and gear assembly 60 4704 014 Motor wiring assembly 69 4704 027 Optical disk 60 9003 112 Pump band 60 4704 032 Pump housing cover 60 4704 036 Pump cover bushing 60 3703 278 Optical sensor wiring assembly 69 4704 025 Hold down kit for detector barrier 68 4700 037 Pump base with detector 60 4704 141 Pump cover installation kit 68 4700 101 Pump heater kit 115 VAC 68 4700 104 2 3 2 Thumb Screw Figure 2 6 Thumb screw removal 2 6 If removal of the thumb screw is necessary first unscrew the thumb screw and lift the hinged half of the pump cover Pry the o ring loose with a small flat screwdriver and then pull the shaft out of the pump cover 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2 3 3 Pump Housing Cover To remove the pump housing cover and access the pump band and Band first release the pump band by opening the latch Remove the four screws holding the cover in place A CAUTION The screw nearest the edge Figure 2 7 must be reinstalled with
21. banner string lists the model number and unique ID of the sampler A gt prompt will appear on the screen when it is ready to accept commands From this menu you can access time date read write and functional tests TIME DATE lt CR gt This command will return the current time and date set in the real time clock chip in the format of HH MM SS DD MM YY TIME DATE HH MM SS DD MM YY lt CR gt Use this command to adjust the time and date in the real time clock chip Note that the format must be followed exactly with one space before and after the equal sign colons between time elements one space between time and date and dashes between date ele ments To retrieve a report of the sampler s program settings type SET TINGS lt CR gt The sampler records the sample and bottle number at the time of each sample event A sampling results report can be obtained by typing RESULTS lt CR gt The RESULTS report contains data from the most recently run program only For a report containing both settings and results type REPORT lt CR gt To begin functional testing type TEST lt CR gt This command activates test mode The display will be blank and unlit As each test is performed related text will appear on the screen As most actual test results will appear on your computer screen the text displayed on the 5800 can be ignored except in the case of the display tests 4 7 5800 Refrigerated Sampler Service Guide S
22. cover Disconnect the solid brown wire from the compressor ter minals Disconnect the blue wire from the other blue wire With the 32 wrench remove the nut holding the green and yellow ground wire on the module chassis For 115V systems refer to Figure 3 19 For 230V systems refer to Figure 3 20 115V Brown Blue Green Yellow Figure 3 19 Electrical connections on 115V compressor 3 20 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System Figure 3 20 Electrical connections on 230V compressor 6 The evaporator sensor is mounted on the sixth coil up on the evaporator Cut the ties holding the evaporator sensor in place and move it out of the frame Figure 3 21 Removing evaporator temp sensor Cut cable ties 7 Slide the refrigeration module out of the way and move the replacement module into its place Module installation 8 Install the evaporator temperature sensor at the top of the sixth coil using the cable ties provided To operate correctly the sensor must be mounted in the exact position illustrated in Figure 3 21 M Note Be careful not to overtighten the cable tie on the sensor body as internal damage could occur The sensor should be snug against the coil but the rubber housing should not be visi bly dented 3 21 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System 9 Connect the wires to the compre
23. g ao Bire oe Sra a ia u37 ano lana E sae 7 i BI A pr Las i i 203 Hh E me e Poemas ES wa coor open P37 le a a i i gs ane MEL e nwe Caos 127144 Pas our urea av i 1 495 alae c 7SRAM CS ADO iie P86 ADOTRIG HS auT2 1 P i 100009F i i AOS re Ao 45 PB7 ADITRIG ours 33 s2A Rue 100009F 10000pF i i o en e volg poo Yao 17 paste gt ours R50 7 02 e AN Teun a AOE E PS oor N UT n 48 z EVENT MARK 100 ne j 2528 Pros af rus wow i i 208 A7 1 02 per La Peas gt i 6 100MA 30v 3 339 i 4 2018 Osho D03 K A10 Pao sov KEYPAD an CRIT 3 3 i An m e 20 Pan gt BACKLIGHT out i i a AE Ea A ta con ar ao aoaea cisa A Suasso al sw f 1 A Ear 1706 HE LOs 33v AL a2 pester FLOW PULSE Y u26 Rows bat D 330pF 5 6V SW TND GND 10 ANALOG TIMER gt AIS 23 15 D06 Fy rr D P6 2 1 50V R124 3 1 i Ar 1 07 y AR Pata Pe PUMP INTERLOCK s M ROWS z cran ev i Ang Zda Wos Hir ma 3 Ca NA Pers SE spex fsck voo aoe pe a i A ay suenos awe TO 0135 cae i ya Aa WE as 625148 PBH BATTERY_TEST ce GPZ HE ROW boa H head U39 A TND 5 ITV IW 132 IL en 5 7avhcioros I 1 16 AIS 1 010 Az E PB17 Hgy gt RUN_ON_BATTERY BEEPER MISO sO PE HS COLE e 0 al sov L 4 i AL ne on E Di RAZA 100 ESE A PB18 BMS E cesta OLS Le voo iad oz 3 tow ur H ANALOG COUNT i 8 ei fone bu ru rd i P818 1CLKO SS ANALOG GOUNT 33 Sty SE Sots er ne am Sues SA md TN ca E use 2 i i a ma ors 22 pz aso 920411040 EJ gt ANALOG_TMER n ame SR coi T pe o 2lsu re 10000p
24. 3V supply falls below the battery voltage The battery supply is from the on board lithium battery The voltage of this battery can be monitored by the CPU through the resistor divider network R41 amp 68 The CPU can load the battery by turning on FET Q3 for testing the battery This chip also has an unused watchdog function U40 is the stepper motor driver for the distributor motor which connects to P11 The CPU sends step commands to this chip to move the distributor When the distributor is to move the encoder drive is also turned on by the CPU This turns on the 4 3 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 4 4 4 1 11 LCD U2 3 5 6 8 4 1 12 Pump Drive U20 21 22 23 24 25 Q8 Q14 Q16 P8 10 4 1 13 Case Heater U33 LED in the distributor opto As the encoding wheel moves pulses are sent back through Schmidt trigger U32 C so that the CPU can count the pulses and determine the distributor position The LCD display operates on 5 volts The rest of the circuitry on the board operates on 3 3 volts Therefore the signals going to the display must be converted to 5V signals This task is handled by level translators U2 and U8 The control signals for the display go through U2 and the data bus through U8 The read write and display chip select signals from the processor are com bined by U5 U6 and U3 to become the Enable signal to the display J1 8 The contrast control volt
25. 68501 USA Phone 800 228 4373 402 464 0231 FAX 402 465 3022 E mail IscoInfo teledyne com Ay WARNING Servicing of this product without proper training and qualifications can potentially expose you to electrical and mechanical hazards that can result in serious or fatal injury Servicing must be performed only by trained and qualified personnel Ay WARNING Removing a module exposes you to electrical and mechanical hazards Always disconnect from AC power before attempting to remove any module Only trained service personnel may remove or replace these modules Ay WARNING The sampler has a safety interlock that prevents the pump from operating when the pump housing band is open The pump is extremely powerful and can injure you severely if the sampler activates the pump during maintenance servicing Remove power from the sampler before opening the pump housing Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List B 1 5800 Refrigerated Sampler mm PO lt E a M B 2 63 SEE DISTRIBUTOR EXPLODE VIEW ON ONIMVYG 010208609 DO SIC S G DETAIL C SCALE 0 250 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List REPLACEMENT PARTS LIST SHEET 2 OF 30 TELEDYNE ISCO REV D DATE PART NUMBE DESCRIPTION 2100004 FAN 12VDC AX FL 231014514 SCREW 8 32
26. Bottle number output to Isco flow meter Event Mark Output 3 second 12 VDC pulse at beginning of sample collection Enable Pin Input Ground this input short to pin 2 to disable sampler operation Leave this input open floating to collect samples White Black Output 14 5 to 12 0 VDC 0 to1 ampere maximum Power for external devices Red Black Output Alarm Off 0 VDC Alarm On 5 VDC Red White Alarm 2 Output Alarm Off 0 VDC Alarm On 5 VDC Orange Black Alarm 3 Output Alarm Off 0 VDC Alarm On 5 VDC Green Black Alarm 4 Output Alarm Off 0 VDC Alarm On 5 VDC Green White Analog 4 20 mA Input Linear current loop signal representing minimum flow rate at 4 mA maximum flow rate at 20 mA This input is paired with pin 13 Blue White Analog 4 20 mA Input See pin 12 1 4 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance Table 1 2 Unterminated Connect Cable Wire Color Signal Name Blue Black Sampler Input Output Parameters Comments Common ground Same as pin 2 Black White Not used Bare with either DB 9 or USB connector with either DB 9 or USB connector Not used All voltage measurements are referenced to common ground on pins 2 and 14 For color pairs the first named color is the predominant color the second named color is the spiral stripe around it This pin is al
27. Cuticable ties ion adan A wie ae 3 4 3 4 Removing rear wall sensor Power supply plate not shown 0 cece cece ee eens 3 5 3 5 Temperature sensor wiring entry at rear of cabinet 3 6 3 6 Temperature verification with the 24 bottle rack oooooomomo o 3 8 3 7 Temperature verification with the bottle locating base 3 8 3 8 Refrigeration service ports 0 0 cece ee een e eens 3 11 3 9 Piercing service port 312 O D tubing with a saddle tap tool 3 11 3 10 Refrigerant dryer before and after installation and coating 3 13 3 11 Refrigeration module components possible leak areas indicated by arrows 3 14 3 12 Protective coverings for suction line and service ports 3 15 3 13 Terminal cover 0 0 eee eect een e een eben eee 3 16 3 14 Condenser fan connections 0 cece cece eee eens 3 17 3 15 Removal replacement of condenser fan 000 c eee o 3 17 3 16 Cut cable tie to free power cord Full power cord length not depicted 3 18 3 17 Removing 230V adaptor from AC power cord 000 ce eee eee ees 3 19 3 18 Remove power cord ooo 3 19 3 19 Electrical connections on 115V compressor 0 00 0c cee eens 3 19 3 20 Electrical connections on 230V compressor 0000 c eee eee eens 3 20 3 21 Removing evaporator temp sensor Cut cable ties 3 20 3 22 Drai
28. Section 2 Sample Delivery System Latch screws Figure 2 10 Pump band latch 2 3 4 Optical Disk 8 Sensor Removal of the optical disk may become necessary either for replacement of the disk and sensor or in order to free the drive shaft Tools 2 Phillips screwdriver 1 39 nut driver 32 Allen wrench To remove the optical disk grasp the pump rotor to hold the shaft in place and remove the mounting nut Carefully tilt and slide the disk away from the sensor If the optical sensor must be removed remove the two Allen screws holding it in place Remove nut Remove 2 Allen screws Figure 2 11 Optical disk and sensor removal A CAUTION Do not allow the disk to scrape against the optical sensor dur ing removal replacement The optical sensor is fragile If it does not need to be replaced set it aside so that it does not get broken 2 9 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2 3 5 Pump Motor and 1 Free the motor from the module s wiring by cutting the Wiring plastic cable tie 2 Remove the nut and optical disk from the pump shaft 3 Remove the four large Phillips screws holding the motor plate on the base Figure 2 12 Removing pump motor assembly 4 Remove the four large Phillips screws that mount the motor to the plate Do not remove the motor gear from the motor shaft Replace as an assembly The brass idler gear bushing engages with the idler gear
29. Section 4 3 8 MHz signal 125 nsec period VB power to RAM About 2 7V on battery 3 3V on AC power 2 5V minimum Battery current minus Load current on lithium battery Should be less than 3yA Best measured with 12V power completely disconnected Reading may depend on meter used Power Fail input to CPU Goes low when 12V power to board falls to about 8 volts RS232 Invalid output If a valid RS232 signal is present on any receiver input this output will be high Analog input pulses About 1200 Hz 0 8 ms period at 10 mA input 4 6 Ground Return for TP4 4 3 CPU Board Tests 4 3 1 TIME DATE Read Write 4 3 2 Sampling Reports 4 3 3 Functional Tests 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply The tests described in this section are accessed through the serial port interrogator port with a terminal emulation program such as Tera Term To connect the sampler to a computer use the optional serial communication cable available with either DB 9 69 5804 042 or USB 60 5804 177 connector 1 Configure your communications software for a baud rate no higher than 38 400 8 data bits no parity 1 stop bit No flow control Auto Detect or VT100 terminal emulation 2 Using your communications software connect to the sam pler Repeatedly type Shift using the computer keyboard until the sampler returns its banner string The
30. TELEDYNE ISCO REV D DATE PART NU DESCRIPTION 10908 DRAW LATCH LIGHT DUTY SST 231014 SCREW 6 32 X 5 16 LONG PAN SST 2313 SCREW SELE TAP 48 X 5 8 LONG PAN SSI 2313 SCREW SELF TAP 46 18 X 3 8 LONG SST 2311 4 SCREW CAP 4 40 X 1 4 LONG SST 232 HEX NUT 8 32 X 11 32 X 1 8 THICK SST 2330104 WASHER FLAT 4 13 ID X 25 OD X 02 THICK SST 2332 WASHER LOCK 6 INTERNAL TOOTH SST 0031 CASE TOP BAND GASKET 604704 MOTOR AND GEAR ASSEMBLY 708 MOTOR MOUNT PLATE l INCLUDES ITEM 107 P SHAFT ASSEMBLY 60T GEAR ER GEAR ASSEMBLY P SHAFT OPTICAL DIS UST SPACER BUSHING P SENSOR WIRING ASSEMBLY CE FARING CYL 188 ID X 310 0D X 1 4 LONG P MOTOR WIRING ASSEMBLY NOTE For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 15 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List B 16 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List REPLACEMENT PARTS LIST SHEET 16 OF 30 TELEDYNE ISCO REV DATE PART NUMBER ESCRIPTION 2313914106 EW MACH NE 10 32 X 3 8 PAN SST
31. Table 4 2 Refer to Section 5 1 5 for standard 5800 pump diagnostics For a complete list of 5800 test points and values refer to Section 4 2 Test points are also highlighted in red on the CPU schematic in Figure A 4 Appendix A Test Point 5 located on pin 5 of U4 A on the CPU gives the fil tered AC signal from the liquid detector Test Point 1 is the liquid detector rectified A to D signal or the input to CR2 When liquid is present this value should be greater than 0 75V as shown at left 1 United States patent 5 125 801 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2 2 Pump Module The pump module is replaceable as a single unit See Replacement Section 2 3 5 for detailed information about the pump 60 5804 128 Ay WARNING Remove power from the 5800 before opening the pump housing The pump is extremely powerful It can injure you severely if the sampler activates during servicing A Ay WARNING Risk of injury or equipment damage Familiarize yourself with the general instructions in Sections 1 6 and 1 6 before proceeding O 0 EN O O A Tim gt y I K Figure 2 1 5800 Pump A Pump Tube F Liquid Detector Cover B Bulkhead Fitting G Latch C Tubing Coupler H Knob D Alignment Notches l Pump Housing E Alignment Collars J Pump Housing Band 2 2 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2 2 1 Pu
32. a cable tie 489 0110 00 Figure 1 13 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance A CAUTION When installing replacing the refrigeration unit the line cord MUST be properly secured This is to ensure that the cord can not be pushed into the enclosure and caught in the fan Cable Tie Bushing Figure 1 13 Secure AC Line Cord Full length of line cord not depicted 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance 1 20 2 1 Pump Functional testing and diags Test points 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Liquid Present 75V _ A A No Liquid Present OV To produce accurate and repeatable samples the pump uses a pump revolution counter and patented non contacting liquid detector The 5800 uses a peristaltic pump housed in a separate easily serviceable and fully replaceable module A CAUTION This sampler has a high performance pump As with all such pumps it relies upon liquid to cool working components If the sampler is programmed to pump in the absence of liquid in excess of 5 minutes excessive heat buildup may damage the paddles rollers and housing Ensure that the liquid inlet is completely immersed For functional CPU board testing through Hyper Terminal see Section 4 3 3 Functional Tests The tests are listed by category in
33. ac_cooo gt H w gw i i czs loas c24 loss ces css ajero 4 cer 4 eso a css fost a ceo 3 Dev Fer i Ya Va 10000pF A E SE Bo Bow y hw re runon BATTERY gt ans pr savn i 2f pis REFER_TEMPERATURE sov Tsov sov sov Tsov sov Tsov Tsov To Ty isv Tev Sov To sav Tev ias 2 15252323 i H e a a LASER ir 4 ses i i m i 55 nm i 6 26K R39 a pes 100005F 5 Pue i 1x ape S S OPT MET INTERLOCK i P8 1 i vas vas e cazo TH 4 iwi Paea la mos 4 120008 er Pee sge uy Yet fe i 3 3V o 744014 remo Rn w20 1 vss Sate ay cre took shes cm 429 i mo Yo 330pF T330pF SPA OPTION i 1 E t sov sov 01 ug SK 50v a 1 H 4 oi SPA OPTION 8 5 ds i i EN sw ve our aF oRa7 j OND Fa ro Het E 2 Ror i i imee F cash 6 om cas PUNP_NTERLOCK at et i H 16v Fev SPA OPTION e CONTROL wo RS Ae Tarna Ro slew 100k Prt T ROTATION 0 V DM ENCODER DRIVE o Ras Cro 10 wo WV z ioe ISENSOR aa 100 sav cu ev tox Taras 1 Ya T Pica WET RED Zon a 2 Fey veche a Ya 100 SE wut Bue Der m 3 cu sawv saav Ro g CEN ae z y a DM_COUNT cn St VH au be o o Yo Vo o fo 5 Ac_coop vyn 1 TEA FERRITE E 5 i co 73 4a cra 027 c29 i Sto 0003 84 1 HERES took TST A 4 99 shez MAA Sov p zov vat oe soy gov Bov 1 bp so SOY sov SOV ia 1s ran grou 17 4 INTERROGATOR OUT ke an POR a hn up A i i 45v i i Y Y Vo o Vo Vo or 12 ram Kour a ares g lo YN PA mm gt i pump x vs cro n 7 i 1 ROTATION nw si ey 15 foun RA 16 yy
34. be considered The volume of the refrigerant in the hoses will vary depending on hose length and the given temperature Care must be taken if the industry standard piercing saddle valves are used These valves tend to leak and should never be left in the system We recommend the installation of brazed in valves Be sure no debris are introduced into the system The valves and cylinder of the compressor are vulnerable to debris Any particulates introduced on the low side will be ingested by the compressor and may cause failure J Ay WARNING Risk of injury or equipment damage Familiarize yourself with the general instructions on pages 1 13 and 1 13 N CAUTION All exposed copper tubing MUST be coated with acrylic paint and then covered with shrink tubing to prevent corrosion 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System 3 4 1 Inspection Troubleshooting and Servicing Tools and supplies All refrigeration module inspection and servicing procedures require opening the rear of the refrigerator Refer to Section 1 7 for removal of the refrigeration module from the cabinet and to Section 1 8 for closing the rear compartment Table 3 2 lists problems that can occur with the refrigeration system and their possible causes Refrigeration repairs are not performed by the factory and on site repairs are not recommended Teledyne Isco recommends replacement of the refrigeration module in the event of
35. locating base place the refrigerator thermometer between bottles three and four Figure 3 7 The refrigerated compartment thermometer can be read after 30 minutes and compared with the displayed refrigerated com partment temperature Section 5 1 8 Figure 3 7 Temperature verification with the bottle locating base 3 8 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System 3 4 Refrigeration Module The following sections describe inspection and servicing proce dures for the refrigeration module WARNING The refrigeration system in the 5800 sampler is a finely tuned system Any small changes will affect the operation of the unit and may compromise the ability of the sampler to meet cooling specifications Teledyne Isco highly recommends replacing the entire refrigeration assembly rather than having the user attempt any repair of the refrigeration system A replacement system comes fully charged and tested It is ready for installation and does not require any further adjustments IF user repairs are attempted please keep the following points in mind The amount of refrigerant required for the system to operate correctly is 5 oz 1 System performance will noticeably degrade with a change of as little as 2 ounces This small amount requires the use of a very accurate scale with resolution of no greater than 1 oz When charging the system the length of hoses used to connect the gauge set must
36. resistor divider network analog voltage on R2 2 750mV powered by the 3 3V analog voltage of the Returns OK to indicate completion board and grounded at analog ground P2 3 The network should be divided to provide 750mV to the liquid detector input P2 2 Additional testing Pump interlock Close the pump interlock input by shorting P8 1 and P8 3 Perform tests T26 and T27 the pump should pass Open the short The pump should fail the tests Distributor Test distributor drive T28 Returns OK or NOT_OK The test commands the distributor to move to bottle position 24 4 9 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Table 4 2 CPU Board Functional Tests Continued Function Command Results Refrigeration Temperatures Test refrigeration T30 A pulse is output first on the compressor control input and output 5V on P1 1 then the refrigerator outputs fan 5V on P1 3 then the cabinet heater 5V on P1 2 There is a 100ms pause between each pulse This test outputs two 100ms pulses on each of the four refrigeration control outputs Returns OK to indicate completion Display refrigerator T33 Returns OK to indicate completion temperature This test reads the resistance on the refrigeration air temperature input P3 5 and P3 6 and returns it as a temperature in degrees C It then reads the refrigeration evaporator temperature input P3 1 and P3 3 and returns it as a t
37. the refrigeration system and its components For a complete listing of replacement parts refer to Appendix B Required Parts and Tools Replacement refrigeration module Nylon cable tie 489 0110 00 For best results soak in water for 1 hour prior to use 2 amp 3 Phillips screwdrivers 1576 open wrench 1 32 open wrench Wire cutters A CAUTION Replacement of individual components may compromise the closed refrigerant system and the protective coatings Removal 1 Cut the cable tie holding the power cord that runs through the refrigeration assembly Cut cable tie Figure 3 16 Cut cable tie to free power cord Full power cord length not depicted 2 Remove the power cord from the refrigeration assembly a Slide the bushing sideways away from the refrigeration module until it is free Use care to avoid bending the refrigeration tubing b Pull the power cord through the module c 230V 50 Hz Systems Only Remove the AC Plug adapter from the end of the power cord by first cutting away the plastic heat shrink tubing Then pull the adapter off leaving just the North American 115V plug 3 19 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System Figure 3 17 Removing 280V adaptor from AC power cord Bushing Figure 3 18 Remove power cord Gently remove the terminal cover of the compressor Pry ing the top edge off with a screwdriver will release the
38. us c OND OM_ENABLE ENABLE 15 DISTRIBUTOR 22 AE 3 4 99 a REF vaaz H MOTOR r sava cre Fane i i gt obrza N i Rig 1 1 33 Spor outze E uouo cas Gancu aeo i RE lt DETECTOR 43 34 Sine SENSE2 pica 5 ea a cm ms ez 7 rzs leur Sem Jos Pres SCHEMATIC par Key 12 3 mer 00k A i us 0 MEA 29 pod og a 4 4 Ps E i gt i rir Ano Hs POND 5800 CPU ET z 0 io 3 A wise Sov Sw sx Bov ES ee a i A I P sum A pz gt re i Gancu Ganci 139775 notes rez pz ane crs i Tose Lis UNLESS OTHERWISE SPECIFIED o 224 E Li0un_oetEcT i gt a RESISTORS ARE IN OHMS 1 100 1 ES l nay us A s cns BO Com so CAPACITORS ARE IN MCROFARADS pl 1 2 E RIO 2 FORWARD SLASH ON SIGNAL NAMI gt Fanou ook 4 cur Ros Ros DENOTES AN ACTIVE LOW SIGNAL w SPA OPTION Facu A SOY iooopF 2 30 50 k f sov FOR PCB 69 5803 012 A 10K Ya Va Ya Va 1 a 1 bi ao o i i HO ONO ao ao Figure A 4 5800 CPU schematic diagram 5800 Refrigerated Sampler Electrical Wiring A 6 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List Replacement parts are called out in the following pages Refer to the call out in the adjacent table to determine the part number for the item Replacement parts can be purchased by contacting Teledyne Isco s Customer Service Department Teledyne Isco Customer Service Department P O Box 82531 Lincoln NE
39. with bushing and cable tie Full line cord length not depicted a 230V 50 Hz Systems Only Attach the 230V plug adapter to the end of the power cord Slide the piece of plastic heat shrink tubing over the plugs Then apply heat of at least 80 C 176 F to shrink the tubing Figure 4 14 230V line cord plug adaptor 4 Reconnect the cable connectors of the replacement power supply to the fan and reinstall the fan with its two mount ing screws M Note When reinstalling the fan ensure that the red power connector goes to the red wire terminal and the black power connector goes to the black wire terminal see Figure 4 10 5 Route the CPU CBA connector cable up through the refrig erator and into the top compartment Connect the har nesses to P1 and P10 on the back of the control panel refer to Figure 4 2 6 Coat the threads of the black bulkhead connector with 737 RTV sealant 800 1002 03 Screw the bulkhead connector 4 21 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply into the refrigerator cabinet by hand until the threads bot tom out Smooth the RTV out to cover the joint 7 Hand tighten the cord grip fitting onto the bulkhead fit ting 8 Close the rear compartment see Section 1 8 Closing the Rear Compartment 4 6 Line Cord Although the line cord comes attached as part of the power 68 4700 050 supply assembly it is possible to replace the line cord only if it becomes damaged
40. you can restart the processor by turning the unit off waiting a few minutes and then turning the unit back on If the problem recurs you can reset the software A CAUTION This procedure will cause most programmed entries and accu mulated data stored in the sampler to be lost and the sampler will revert to factory default settings If this operation is per formed it will be necessary for you to reprogram the unit to meet the specifications of your installation Record your pro gram settings and download any data before performing a soft ware reset To reset the software 1 Disconnect power to the sampler 2 Hold down the Stop and Enter buttons together and recon nect the power Select this option to view the system IDs This function reports the unique ID for the sampler and its hardware and software versions These IDs are factory set 1 Select the SYSTEM IDs option and press Enter 2 The first line lists the model number The second line lists the unique ID for the sampler Press Enter to continue This screen lists the version numbers of the installed hardware and software Press Enter to return to the SELECT OPTION lt gt screen 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance 1 6 Major Assembly Removal and Replacement 1 6 1 Removing a Module 1 6 2 Replacing a Module 1 6 3 Safety Precautions Teledyne Isco designed the sampler for easy field replaceme
41. 15 Panes es 5 SS REFRIGERATION BEEPER ajrat our al we ue lest E fi HA i RESET SILAS nov ayy rasos oso RATO ez wr 2170 ic TRST A dr ewe ie eo a one hos Piera H nesi ak as K T 1 MNSZ52328 s is 1 o 25 0022 200 yossu S nese EAS fate LE moo oo PR 98 Irie Te gps sw oo 3 at a a Sv i i ho 1 00 Ea n i i EG a orp En 33V HIV ENEH PA17 SCK1 AE RS232 XMIT ENABLE 7 MCP23508 VNO2HSP tow UA i Aos any Wide Doz JOISPLAY cS lt Gyg 1NCS4 Pata TADI NTRI E mo o o4 A 7 Prov tav EA Forwaro i i ra ES 203 bed ef Beeper 1 Lae oxo Is 7avucrctos ano P msz Eaire CN i as 1 04 Bee PAZO SCKZ 1 1 a i i Ade AE sas pond ao puue rwo 1 a da PELE wv i TWA Bhs 1 08 42 Doe NOE NRO PA22 RXD2 sawv ban 2 i R72 1 on i i Age a rw RUS ZAR aaa uso se u SERTE Forwaro 9 i P NUB NWRT BADA ig H 499 E i f ra His vos nog Roda PADS MOS LSI los ve ae penn w 100K ui A an Mo 1 010 PAZ6 NPCSO NSS Ma 10 EXPANDER CS jo 1 ik E or 33 re S i Y VAN vous pil ataoseL PA27 NP0S1 Lae R75 ve o E crm i Des 1 i a tie font p Tus 7 e PAZ NPGS2 HOL Took 4 J i e i i y E H R77 al Paze npess pot vn vov a ey i cv PA on be pi 3 100 lt 7 tbo 18 VATCHDOG ms E o STE alens yarosse i sav oe i i ne A a 171 013 ida 1 00 ve E Ter NwoovF wok 2 aso io 47 1 i i i a Loroossst paras st 160 ov i i awo av i i aie LANH Reser O Nast woe or gru WAKEUP i i 3 i A aw 46 D wa na 14 ws i Ot i As oo s Ps 00 wakeup Hi amp car i
42. 17 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System a For 230V units loosen the screw on the top hold down tab to free the harness z rai Top hold down a tab Ribbed Smooth Smooth Ribbed Figure 3 14 Condenser fan connections 3 Remove the three lock nuts holding the fan assembly in place Remove the fan assembly and vibration cushion Lock nuts 3 Vibration cushion Figure 3 15 Removal replacement of condenser fan 4 Place the new vibration cushion and fan assembly on the floor of the refrigeration module aligning the holes in the base over the threaded mounting studs and secure with the three lock nuts 5 Route the fan harness around the drip tray and connect to the relay taking care to connect the ribbed and smooth wires correctly as shown in Figure 3 14 a For 230V units also route the harness wires around the right side of the terminal box and under the top hold down tab Tighten the screw 6 Replace the terminal cover taking care not to pinch or bind any of the wires 3 18 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System 3 4 5 Module Replacement The refrigeration module is designed to be replaced as a complete unit Unlike the other modules the refrigeration module is voltage specific Be sure to order the replacement module and or appropriate components for your AC mains power Table 3 1 on page 3 1 contains part numbers for
43. 30 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List REPLACEMENT PARTS LIST SHEET 30 OF 30 TELEDYNE ISCO PART NUMBER DESCRIPTION 231611630 SCREW SELFT 14 X 2 LONG PANHEAD SST 604104137 REPLACEMEN ER ASSLY IISV 604704156 REPLACEMEN ERY BACKUP ASSEMBLY 005804135 REPLACEME EATER ASSY 230V NOTE de For current prices and quotations on parts contact Isco Service Department This list is subject to change without notice B 31 B 32 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List B 2 Bottle Configurations Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List 604702065 REPLACEMENT PARTS LIST SHEET 2 OF 14 TELEDYNE ISCO REV DATE 082107 ve PART NUMBER DESCRIPTION CAP W POLYETHYLENE FOAM L 602103095 LITER POLYPROPYLENE BOTTLE 6 604 04022 BOTTLE RACK BOTTLE RACK ASSEMBLY LITER 2 6047 18 INCLUDES ITEMS 8 II amp 16 NOTE For current prices and quotations on parts contact Isco Service Department This list is subject to c
44. 37 RTV to the threads of the cable s bulkhead fitting 3 Screw the bulkhead fitting into the cabinet wall until the threads bottom out Smooth the excess silicon sealant around its base to seal the joint 1 Dow Corning is a registered trademark of Dow Corning Corpo ration 3 6 3 3 2 CPU Temperature Sensor 3 3 3 Sample Compartment Thermometer optional 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System 4 Tighten the black plastic cord grip fitting over the bulk head fitting 5 Clean the control panel s mounting surface on the face of the refrigerated compartment This will help ensure that the gasket will seal the enclosure 6 Install the ferrite bead 4 from the cable connector Wrap the cable one complete turn around the bead and snap it closed Figure 3 2 7 Attach the new cable to P3 on the control board ensuring that the connector is oriented correctly 8 Align the control panel over the mounting holes and secure it with the mounting screws Torque screws 1 8 to 2 0 Nm 16 to 18 in lbs 9 Using the two plastic cable ties mount the black sensor on the sixth coil of the evaporator as shown in Figure 3 21 To operate correctly the sensor must be mounted in the exact position shown M Note When installing the black molded sensor be careful not to overtighten the cable tie on the sensor body as internal damage could occur The sensor should be snug against the coil bu
45. 4000 NUT LOCK 6 32 NYLON INSERT SST 60470801 INTERFACE CABLE MOUNT PLATE 694104017 INTERFACE COMMUNICATION HARNESS 694103096 GASKET INTERFACE CAP NOTE For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 21 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List A CAUTION When installing replacing the refrigeration unit the line cord g MUST be properly secured Hold the line cord taut to remove B any slack and attach a cable tie as shown This is to ensure that the cord cannot be pushed into the enclosure and be caught in the fan B 22 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List REPLACEMENT PARTS LIST SHEET 22 OF 30 TELEDYNE ISCO REV D DATE RIPTION RATOR ASSEMBLY IISV EMBLY 115V EMBLY 230V RATOR ASSEMBLY 230V FT cpm FF AAA wri j i j J 1 1 1 1 NOTE For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 23 Isco 5800 Refrigerated Sampler Service Guide Appendix B R
46. 5 3 56 Test Distributor anti god aie AE aoe ee tati a 5 4 5 1 7 Test Flow Meter Port 0 0 cece cee een teens 5 6 5 1 8 Refrig Temperature 0 0 0 ce eee tenes 5 6 5 1 9 PCB Temperature 00 ccc cece eee eee ene E S 5 7 5 1 10 Input Voltage 2 oeras eee renra sena ee ee ee eae eae ee als 5 7 51 11 Battery Voltage pregis rerai pu E AAA eS Rs 5 7 5 1 12 Loaded Battery Voltage 0 0 0 ccc cette nee 5 8 5 1 13 Display Analog Input 0 0 ee eens 5 8 Appendix A Electrical Diagrams Appendix B Replacement Parts List B 1 5800 Refrigerated Sampler 0 0 ccc tent eens B 2 B 2 Bottle Configurations seis caeco ie ccc ccc eee a a nne B 32 List of Figures 1 1 16 pin rear connector 20 ccc eee eee een nee nee 1 4 1 2 5800 PUMP ce id tele edges Bod eta hoe ate de aera ye ates ROSE aco acd ee 1 6 1 3 Rollers A and guides B on the pump rotor cee cece eens 1 7 1 4 Wetted parts socs ses coe ee ee Soe a eee dea SRA eee eae dees 1 10 1 5 5800 Sampler to RS 232 serial communication cable 1 11 1 6 Self tapping screws reinstallation 0 0 cece eee eee 1 15 1 7 Remove back cover and insulation 0 0 c cece eee eee eee 1 15 1 8 Cut cable tie from line cord Full line cord length not depicted 1 16 1 9 Remove the refrigeration module mounting screws 1 16 1 10 Rear view with module removed Adhesiv
47. 5800 Refrigerated Sampler Service Guide ae TELEDYNE ISCO Everywhereyoulook Part 69 5803 093 Copyright O 2013 All rights reserved Teledyne Isco Revision C April 2014 Electrical Safety Isco 5800 Refrigerated Sampler Service Guide Safety The Isco 5800 Refrigerated Sampler is a definite purpose device intended for use only with compatible Isco equipment Except as described in this manual do not use this product with any other manufacturers equipment or for any other purpose Use for any purpose not described in this manual could cause personal injury or property damage The sampler requires a nominal 115V 60 Hz or 230V 50Hz AC power Refer to the nameplate and ratings label inside the refrig erator compartment The power input is through the mains power cord at the back of the sampler The sampler is protected by an internal thermal cut out Additionally the sampler con troller circuitry is protected by an internal fuse A Ay WARNING Electrocution hazard Never manipulate electrical switches or power connections with wet hands or when your feet are in contact with water A Ay WARNING AC electrical power must meet the applicable electrical code requirements for your installation and must be provided with an earth ground connection If necessary consult with a certified electrician to ensure that AC power is provided in accordance with the local electrical code The AC power cord of this device is
48. 8 233 0190 41 all x2 Hinges 60 4703 050 Door Latch Assembly 60 4704 021 Flip Cover 60 4704 020 12 VDC Axial Fan in cabinet wall 210 0004 01 3 2 Door The refrigerator door can be ordered as a replacement part with gasket and hardware already installed Attach the new door to the cabinet using the four hinge screws provided 3 3 Temperature Sensors The 5800 has two refrigeration temperature sensors one attached to the evaporator coil to measure the evaporator tem perature and the other mounted on the refrigerator s rear wall to measure the refrigeration air temperature The two refrigeration temperature sensors are part of the temperature sensor cable assembly kit see next section Additionally there is a temperature sensor located on the CPU board Optionally you can measure the cooling temperature of the sample compartment using a thermometer in liquid See Table 4 2 Refrigeration Temperatures and Sections 5 1 8 and 5 1 9 for instructions on how to view temperature readings 3 2 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System 3 3 1 Temperature Sensor Before accessing the temperature cable for replacement ensure Cable Assembly that all safety practices described in Section 1 6 are followed Kit 69 5804 054 Required Parts and Tools e Replacement cable assembly kit e 2 Phillips screwdriver e 3 Phillips screwdriver e Wire cutters e 15 16 open wrench e Clear
49. ASE BOTTOM BAND GASKET 004703001 POWER SUPPLY COVER 604703074 EMPERATURE SENSOR HOLDER 62470000 EPLACEMENT LINE CORD W EUPOPEAN PLUG 230V i CLUDES ITEMS 113 4 114 695804054 T PERATURE SENSOR WIRING ASSEMBLY 694704050 RE TE U LISV LINE CO REPLACEMENT LINE CORD 149901100 E 262123516 H R R EUROPEAN ADA PLUG AT S BING 40MM 1 6 BLACK P 604704 H PLACEMENT POWER SUPPLY LISV CLUDES ITEMS 13 35 amp 39 S PLACEMENT POWER SUPPLY 230V CLUDES ITEMS 13 35 39 113 amp 114 FERRITE PED AROUND E MP E SENSOR 91 6047 E S E S NOTE For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 19 ice Guide 5800 Refrigerated Sampler Serv Appendix B Replacement Parts List Isco B 20 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List 605802010 REPLACEMENT PARTS LIST SHEET 20 OF 30 TELEDYNE ISCO REV D DATE PART NUMBER DESCRIPTION 149100105 CAP SIZE 17 W O GASKET 202407318 O RING SILICONE 975 ID 210 CROSS SECTION 231611620 SCREW SELF TAP 14 X LONG SST 23291
50. DATE PART NUMBER DESCRIPTION 209003023 ING BELT SIDED 120 GROOVES 231116304 SCREW CAP 4 40 X 1 4 LONG SST 231310108 SCREW SELF TAP 4 X 1 2 LONG PAN SST 231310310 SCREW SELF TAP 8 X 5 8 LONG PAN SST 231914901 SCREW 3MM X 6MM PAN SST 233010403 WASHER FLAT 4 13 1D X 25 0D X 02 THICK SST 23301120 WASHER FLAT 8 19 ID X 38 00 X 02 THICK SST 603113029 CASE TOP BAND GASKET 4103014 DISTRIBUTOR BASE 5804029 REPLACEMENT DISTRIBUTOR ASSEMBLY 4104034 REPLACEMENT DISTRIBUTOR SHAFT ASSEMBLY 04 SENSOR MOUNT PLATE INDEX SENSOR R MOTOR amp PULLEY ASSEMBLY 26 ENSOR WIRING ASSEMBLY OR MOUNT ACCESSORY KIT S 14 30 amp 19 ENSOR ACCESSORY KIT S dla 12 29 19 amp 95 02 0 NOTE I For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 5 ice Guide 5800 Refrigerated Sampler Serv Appendix B Replacement Parts List Isco CONTROL PANEL Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List 605802010 REPLACEMENT PARTS LIST SHEET 6 OF 30 TELEDYNE ISCO RYD DATE PART NUMBER DESCRIPTION 231611620 SCREW SELF TAP 14 X
51. EST PASSED will appear If not the message COOLDOWN TEST FAIL will appear 3 23 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System 3 24 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 4 1 5800 CPU Circuit Board Description 4 1 1 Processor Ull This section contains circuit descriptions of the 5800 s CPU and power supply as well as functional CPU board testing Sche matics can be found at the end of the section The following section describes the operation of the CPU compo nents Various peripherals are built into the processor Features include e 10 bit analog to digital a to d converter e 8to 1 multiplexer which allows 8 external analog inputs to be converted one at a time e clock circuitry that allows the processor to run at different speeds e an internal real time clock that can run on battery e two crystals a 16 MHz for the processor clocks and a 32 768 KHz for the real time clock e 2 UARTS for serial communication e counter timers that can count pulses from external sources e large number of parallel input output ports e internal chip select circuitry e internal RAM e operates on 3 3 volts e has 24 address lines allowing it to address 16 M bytes e 16 bit data bus e 2 digital to analog converters d to a The processor has a 16 bit data bus so that two bytes at a time are handled between the CPU and memory Eight bits of the data bus also g
52. F T ar leav jos 4 s h4u25 8 F i i E 1014 5H Raat Sar ATOIMSSB00A PB21 ZO lacy ari CoL i or Tee i i Zlvss 14015 na Ass na22 1000 SE PUMP COUNT ta E ro oe AAA rua _ 10000F 10000pF E er es al Ke Ts alo f i e 40 a 2824 00 pz gt MEAT oo Ar espe 100WA sov 3 Lal ros run Ser tele F 4 Frew o i i KExaOIETS oo 35159 pose rece case 297 ES am I WCP2350E i z d cs Y 3 3 i i o Dor 35109 PB28 TI0A2 0M ENABLE gt i Fa Se ao 330 AM BEV SN ciso ered ADES 00 war i i e De at 2827 1082 PE JoM_RESET ud E i a Le eu o o l 1 wv DOS 35403 m 33v Doct tae per ao No e Site D04 4 De Pao rouKs 88 gt gt TRANSCEIVER ENABLE one sov t i cs oe 40108 PAINONI PSI DISPLAY RS alee m 0 eon i Dos Aros PA2 TIOBS FEE gt DISPLAY RW on callers ours 81 1t BOV 43 3y D07 3507 PAS TCLK4L Go so f 10000pF Gow COM COM i DOB 37108 Paa ions puu rwo fo vas Ison R122 Sanoati i ozo f 1 Do os PAS TIOBA yy gt PUMP REV Bee Ia vale 2v sav weet rus rs A oF tothe ye Soio PASTS 75 TST EIS WOOT s ou_encooenorve CASE HEATER ol wath Sov 5 i i o ty s Tion parsons be Pe So do uss E oss Si i 1 4 Fan DMZDIRECTION a Ty 15MB5919 i 1 p i ES Al oe Band PA6 RGO POWER FALL sv ala ESHE Vectra our 2 ae hae gt o soy e stav er pe 1 FLASH_CS ice von Die 4 D14 PAIO IROI y E 15 DSI HEATER N out var 1 NOE 3 2 TOE ver Hi e Ko 34 PAw Roz ae ho cps PUMP_ENCODER_ORWE H sura 50V EA ra peH 0
53. G by unscrewing the large black knob 1 3 Unlatch the Pump Housing Band K 4 Pull the tube A away from the bulkhead fitting B and disconnect the tubing coupler and suction line You may have to cut the pump tubing to release the coupler 5 Pull the old pump tube through the pump 6 Thread the new pump tube through the pump Note that the short end inlet should extend from the top opening 7 Align the blue collars with the alignment notches 8 Close the liquid detector cover and secure it tightly with the large knob 9 Close the pump housing band and secure it with the latch 10 Reset the pump tube counter See the Resetting the Pump Tube Alarm example 11 Take a dry grab sample Section 4 4 to test the new tube 12 Reconnect the suction line Pump Tube Life Several factors shorten the pump tube life including e Incorrect installation e Abrasive materials suspended in sample liquid e Frequent line rinses e Long purge cycles such as those used with long suction lines To extend the life of the pump tube e Always use Isco pump tubes e Install the tube properly aligning the blue collars correctly in the notches e Follow the natural curve of the tube when routing the tube around the pump rollers e Minimize the line rinses and sampling retries in the sampling programs e Use the shortest possible suction line 5800 Refrigerated Sampler Service Guide Section 1 Intro
54. NO 1 4 3 Cleaning the Pump Debris should be removed from the rollers and guides to keep the Rollers pump operating efficiently and to extend tubing life Remove loose debris from the pump rollers and guides with a stiff nylon bristle brush If debris has built up and cannot be removed with the brush scrape the rollers or guides with a plastic or wooden tool to loosen the debris N CAUTION Do not use a metal tool This might damage the plastic rollers and guides 1 9 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance 1 4 4 Cleaning the Pump Housing 1 4 5 Cleaning or Replacing Wetted Parts Figure 1 4 Wetted parts A CAUTION Never use lubricants or solvents on the pump tube or rollers Many chemicals they contain will attack the plastic and sili cone causing irreparable damage to the pump Remove loose debris from the pump housing with a stiff nylon bristle brush If needed flush debris from the housing with water Do not spray with pressure This might force water through the seals and bushings and damage internal compo nents For general cleaning you can wash the strainer and sample bottles with a brush and soapy water then rinse with clean water You can clean the liquid path through the wetted parts Figure 1 4 by placing the strainer in a cleaning solution and pumping it through the delivery system Next place the strainer in clean water and pump it through the delivery
55. OL PANEL ASSEMBLY NOT CHINA 609804031 INCLUDES ITEM 13 35 REPLACEMENT CONTROL PANEL CHINA 003804132 INCLUDES ITEMS 13 35 NOTE l For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 9 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List egni A ts B 10 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List REPLACEMENT PARTS LIST SHEET 10 OF 30 TELEDYNE ISCO REV D DATE PART NUMBER DESCRIPTION 20240932 O RING SILICONE 1 162 ID 210 CROSS SECTION 231014314 SCREW 8 32 X 7 8 LONG PANHEAD SST 231611620 SCREW SELF TAP 14 X LONG SST 605804128 EPLACEMENT PUMP ASSEMBLY 694703039 E GASKET 694704004 PUMP INTERFACE 094104064 LKHEAD TUBE ASSEMBLY 231610908 EW SELF TAP 1 4 X 1 2 LONG SST 609004137 P TUBE QUIC SCONNECT NOTE For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 11 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List PUMP EXPLODE VIEW B 12 Isco 5800 Refrigerated Sampler S
56. STERRDGATORIN O 3 3v ua saav st iam E EN A i 1 SENSOR T 1 5 1 bi H vee bi i Ras Ran o ALT RS232 RX Ras patron ce cs i ep seo A lus E mor 19 pouz e t vm Boos eor wane 83 BR o vost ave i dk AV ravacioraz PUMP_ENCODER_ORWVE al se 3 o Pere Bor woo sav tal oy z d i AC oem gt WET Pos gue 3 en si A HEN sw 50v 14 ASER 787887 gN o D o BACKLIGHT i a oo e Se ASTI VOLTAGE 3 i a rear taz w Hoy e 85252 XT ENABLE me pix TH seet penetra CONTRAST VOLTAGE gt OPTO SENSOR BEAD cus cvs D ees Sas ure 2 des 7052 ce uw cE out SRAMLCS PA 402 4850 00 H SPA OPTION 1 1 m PERA RoI a VBATI ONO att i sov sov 1 a puwecowt YO S ao ok m a cm cs m0 say ms 17069554 33 kot een veo 2 vo i ae se ne Tanca SMBJ7 SA 1000p J SUB7 5A 1000pF acs an Yo Less ale welt sw saw a i eu FSv 30 T Sov LEN Sov w om pe i Bad 30K op ev WBR0530 RESET 13 gt A Soy TRANSCEIVER_ENABLE E Sal ge asl asv 1 a ia 50V CRIS 10 4 1 i waa ssw saw HH REFRIGERATION sas ese al Pao a Mov DISPLAY i gt de REFER SHEA SA E saav DELAY I SPA OPTION o D Vo o o ve c62 REFER_FAN sal Ea R R21 RIS o p i avin B5300 13 y ej NOE 45 ashr z 100K 100K us 2 i o nas in ovr anne M Ba ws ral q Rizo ave as Tan 16v oIsPLAY_cs HSO 83 5 un innl aoa ros avn DISPLAY AS A 1 is e po pF yo 33va Hi zl _ono DISPLAY AN ES A Hor nye urs x poz esoo es 5300 13 emo le eno le ons AS 5 enol 3 2 a ae Mm 5 PIO a me le em E 1P578227 1 FE a am aisa T 330pF em
57. System 2 7 Disassembling the Begin disassembly by removing the distributor module according Distributor to steps 1 through 5 in Section 2 6 1 Remove the nut and washer holding the ferrite bead in place Figure 2 26 2 Remove the two screws and washers from the stepper motor mounting plate 3 Slide the stepper motor assembly slightly toward the dis tributor shaft to disengage it from the timing belt and remove it 4 Remove the two screws holding the optical sensor in place 5 Slide the sensor away from the index disk and remove tak ing care not to scrape it against the index disk Stepper 7 motor Ferrite Timing belt Optical sensor Figure 2 26 Removal of stepper motor and optical sensor M Note The optical sensor is fragile Set it aside so that it does not get broken Inspect the sensor and replace if broken 6 Remove the three large screws holding the cover plate in place Remove the plate to expose the timing belt 7 The timing belt distributor shaft assembly and band gas ket simply lift out of the base 2 21 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Cover plate Distributor shaft Timing belt Gasket nT L z iw co IR Figure 2 27 Distributor assembly exploded view 2 8 Rebuilding the This section details the replacement steps for each of the dis Distributor tributor comp
58. X 1 8 LONG PANHEAD SST 231515964 SCREW ADJUSTING 3 8 16 X 2 SST 23161162 SCREW SELF TAP 14 X LONG SST 2321180 JAM NUT 1 4 20 X 44 THICK SST 2321192 JAM NUT 3 8 16 X 96 THICK SST 23291400 LOCK NUT 46 32 SST W NYLON INSERT 23301904 WASHER FLAT 390 1D X 63 OD X 063 THK SST 18 8 410304 TILT STOP 3 3 3 3 4103044 RIGHT STOP 4103045 LEFT STOP 59 FAN MOUNT PLATE 800 HOUSING WITH FOAM ASSEMBLY INCLUDES ITEMS 20 25 amp 31 EPLACEMENT DISTRIBUTOR ASSEMBLY FOR DETAILS SEE DISTRIBUTOR EXPLODE VIEW 2923001 ISTRIBUTOR ARM NUT 4104033 EPLACEMENT DISTRIBUTOR ARM ASSEMBLY 4103164 TUBING AR 4103165 TUBING ARM PIVOT 410802 TUBING ARM MOUNT 31313908 SCR SLFIPG 10X1 2 605804004 SHORTENED DIST ARM FOR 4X20 LITER 4 5804012 5804029 NOTE I For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 3 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List 3 14 DISTRIBUTOR VIEW NARS aN JE Lily B 4 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List 605802010 REPLACEMENT PARTS LIST SHEET 4 OF 30 TELEDYNE ISCO REV D
59. ack wire to the black terminal 3 Route the wires so that the ferrite bead is on top of the motor refer to Figure 2 15 4 Clamp all four wiring harnesses to the motor body with a cable tie 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Terminal Ferrit errite bead connectors Cable tie Figure 2 15 Pump motor wiring harness AN CAUTION If the ferrite bead is not positioned as shown in Figure 2 15 the pump module will not fit into the 5800 cabinet properly as shown in Figure 2 3 resulting in the gasket not sealing when the pump module is attached to the cabinet 2 3 7 Rotor The pump rotor is attached to the gear shaft with a screw on the side with two posts and a nut on the other side Figure 2 16 Always make sure the screw and nut are on the correct sides The rotor has no top or bottom the two posts will always be posi tioned correctly regardless of the rotor s orientation Lock nut on opposite side Figure 2 16 Pump rotor and hardware 2 12 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2 3 8 Gasket Replace the gasket using the following steps as shown in Figure 2 17 1 Always begin by pressing the gasket into one corner of the base 2 Pull the gasket taut then press the gasket down into the opposite corner This prevents the gasket from being unevenly distributed in the groove ensuring the integrity of the seal 3 Press the oth
60. age comes from a d to a output from the CPU directly to J1 5 The backlight control signal goes through FET Q1 to switch the backlight on and off Power is supplied to the display from linear 5V regulator VR1 The pump motor connects to P7 and the interlock switch in the pump connects to P8 If the pump band is in place and latched the magnet in the band activates the reed switch in the pump housing and closes the circuit for the interlock There are redundant interlock circuits operating from the interlock switch One circuit takes the signal from the switch through Schmidt triggers U32 F and U32 E to the AND gates U20 and U21 With this signal present at the AND gates the Pump Forward or Pump Reverse drive signals can get through to the opto isolators The other lockout circuit takes the signal from the switch through Schmidt triggers U25 F and U25 E These drive opto isolator U24 which produces a low signal to the gate of Q10 Q10 turns on and drives the gate of Q8 high turning it on Q8 is then the path to ground for the motor current when the H bridge is active to drive the motor For the motor to be driven forward the forward drive signal from the CPU goes through AND gate U20 and opto isolator U22 The low signal from U22 then turns on Q14 one leg of the H bridge which sources current to the motor on P7 1 The low signal from U22 also turns on Q11 which inverts the signal and provides a high drive to Q9 another leg of the H bridge
61. an abort the test by pressing the Enter but ton The voltage reading is normally between 2 4 and 3 1 VDC If the voltage is below 2 4 VDC the internal battery should be replaced Contact your authorized Isco service facility or the Teledyne Isco factory for assistance M Note Should there be a loss of AC power and the internal battery s loaded voltage is below 2 4 VDC the sampler might lose data and settings from its memory It is recommended that you retrieve the data and record the program and configuration set tings in case of memory loss The ANALOG INPUT diagnostic displays the 4 20 mA current loop input to the sampler This diagnostic tool is helpful when troubleshooting an analog input from a flow measurement device When you start this test the sampler will display the current reading until you press the Stop or Enter button There is no pass or fail SELECT DIAG lt gt ANALOG INPUT ANALOG CURRENT _ MA 5800 Refrigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics To display the analog input current 1 Select the ANALOG INPUT option and press Enter 2 The display shows the current reading until you press the Stop or Enter button The display can include currents above 20 mA and below 4 mA and updates every 10 seconds The reading should be within half a milliamp of the actual current input 5 9 5800 Refrigerated Sampler Service Guide Section 5 Elec
62. and The pump is extremely powerful The pump can injure you severely if the sampler activates the pump while you are working on it Remove power from the sampler before opening the pump housing 2 Refer to Figure 1 2 Release the latch H securing the metal pump housing band K 3 Swing the pump housing band away from the pump hous ing 1 5 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance 4 Inspect the following a Pump tube Look for excessive wear caused by the pump rollers and for cracks along the sides of the tube Cracks might not be apparent unless you flex or squeeze the tubing If cracks or excessive wear are evi dent replace the pump tube Section 1 4 2 Figure 1 2 5800 Pump A Pump Tube F Liquid Detector Cover B Bulkhead Fitting G Latch C Tubing Coupler H Knob D Alignment Notches l Pump Housing E Alignment Collars J Pump Housing Band A CAUTION This sampler has a high performance pump As with all such pumps it relies upon liquid to cool working components If the sampler is programmed to pump in the absence of liquid in excess of 5 minutes excessive heat buildup may damage the paddles rollers and housing Ensure that the liquid inlet is completely immersed 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance Figure 1 3 Rollers A and guides B on the pump rotor b Pump Rotor Lo
63. aracters on each line Observe the display to determine pass or fail Additional testing Clock Speed In the test mode the master clock output pin is enabled to allow measurement of the clock frequency Exiting test mode disables this pin Additionally the duty cycled pulses to the heater resistor essentially stop reduced to 0 01 during TEST mode These pulses also are restored when TEST mode is exited Measure the clock speed MCKO on TP14 8 MHz signal 125 nsec period Pump Test pump drive T26 On off ratio should be between 0 8 and leonard Optical sensor connections les P9 1 power to LED P9 2 power to LED If the optical sensor sees motion the test P9 3 3 3V to sensor P9 4 signal from returns On Off ratio and then OK sensor If not the test returns NOT_OK Connect either the actual motor or a simulator at P7 1 and P7 2 Activate the pump drive output in forward mode Test pump drive T27 On off ratio should be between 0 8 and pavers Optical sensor connections Mee P9 1 power to LED P9 2 power to LED If the optical sensor sees motion the test P9 3 3 3V to sensor P9 4 signal from returns On Off ratio and then OK sensor If not the test returns NOT_OK Connect either the actual motor or a simulator at P7 1 and P7 2 Activate the pump drive output in forward mode Test liquid detector T29 The test will return 20 readings of the This test requires a
64. as shown in Fig ure 2 21 Secure the shield with the four 6 x98 self tap ping screws 2 16 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Figure 2 21 Install heat shield inside cover 3 Temporarily close the pump cover to check the heat shield alignment The hole in the shield must fit over the large knob on the pump assembly If the shield hits the knob loosen the four screws and adjust the shield When the alignment is correct tighten the screws 4 Position the heater on the sampler as shown in Figure 2 22 Align the edges of the slot in the heater against the lower left corner of the pump assembly Figure 2 22 Install heater under pump 5 Secure the heater in place with the two 14x2 self tap ping screws Tighten the screws until fully seated 6 Refer to Figure 2 23 and secure the AC line cord just inside the notch in the cover with the clip and the 48x s self tapping screw 2 17 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 3 di 30 m 1 2 ih Figure 2 23 Install line cord clip just inside the notch in the cover 2 5 Distributor Drive circuitry Functional testing and diags Test points Tools required for service 2 18 The distributor directs collected liquids to the bottles Movement of the distributor is controlled by user specified program settings For a description of distributor dr
65. by current draw from the battery Remove the 12V power from the board to perform this test Using a meter that can read down to 0 01 millivolt measure this current by measuring the voltage between TP8 and TP90 The voltage should be less than 4mV 4 10 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Table 4 2 CPU Board Functional Tests Continued Function Command Results Display flash memory T38 Each flash chip has a unique 16 character serial number serial number in hexadecimal format Returns OK on a new line after the serial number line when done This test returns the serial number of the flash memory chip Turn off backlight T39 Turns off the backlight for the LCD module Returns OK to indicate completion Turn on backlight T40 Turns on the backlight for the LCD module Returns OK to indicate completion Turn on CPU heater T41 Returns OK to indicate completion This test applies full power 100 to the heater resistor on the CPU board This will last for 10 seconds and then the power will be turned off Test Data Save data in flash T99 Returns OK to indicate completion memory This command saves the calibration values for the analog input measured in tests T04 TO9 and T20 It also saves the current real time clock time and date as the time the board was tested Therefore the real time clock should be set before issuing this command Retrieve time of CPU T98 Returns
66. cing the refrigeration module are listed on page 3 10 Unlike the other modules the refrigeration module is voltage specific Be sure to order the replacement module and or appropriate components for your AC mains power Table 3 1 con tains part numbers for voltage specific components and for the refrigerator cabinet For a complete listing of replacement parts refer to Appendix B Table 3 1 Replacement Parts for 5800 Refrigerator Refrigeration Module 115V Entire Refrigeration Assembly 60 4704 028 Replacement Condenser Fan Assembly 60 4704 038 Capacitor Relay Kit 60 4707 002 Overload 13 9A 210 0002 06 Compressor 210 0001 09 Refrigeration Module 230V Entire Refrigeration Assembly 60 4704 052 Replacement Condenser Fan Assembly 60 4704 056 Capacitor Relay Kit 60 4707 004 3 1 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System Table 3 1 Replacement Parts for 5800 Refrigerator Continued Overload 6 8 A 210 0002 08 Compressor 210 0001 10 Other Module Parts and Supplies Dryer 209 0192 14 Shrink tubing for service ports 262 1225 16 Cork insulating tape 090 9020 13 Orifice 60 4704 093 Orifice bushing 60 4703 099 Refrigerator Cabinet Door Assembly 60 4704 047 Door Gasket 60 4703 070 Leveling Screws Feet 3 8 16x2 231 5159 64 Jam Nut 3 8 16x 56 thick 232 1192 00 Flat Washer 390 ID x 63 OD x 63 thick SST 18
67. com ponent failure If it is still deemed more practical to repair the system on site repairs must be performed by licensed service personnel only Consult your local laws regarding refrigeration repair Copper Tubing Tubing must be cleaned and capped copper refrigeration grade DO NOT use general pur pose tubing Tubing sizes 250 O D x 190 I D 312 O D x 280 I D Saddle Tap Tool For 312 O D service ports Silver Solder Solder must be refrigeration grade silver DO NOT use general purpose solder Lacquer Paint Heat Shrink Tubing Brazing and all exposed metal must be coated with lacquer paint to prevent corrosion Table 3 2 Refrigeration System Troubleshooting Compressor tries to start then stops has excessive current draw Compressor runs hot trips thermal breaker Outer coil does not heat up while unit is running Cause Plugged orifice Compressor failure Refrigerant leak Action Replace refrigeration module recommended Compressor does not start at all Relay or capacitor failure Replace component see Table 3 1 Higher than normal pressure on one or both service ports Refrigerant overfill Water inside the tubing forming ice Drain and recharge the system see Section 3 4 3 Dented pinched or bent tubing Repair or replace damaged tubing Poor performance compressor running constantly 3 10 Air leak Ensure t
68. condenser fan 3 17 dryer 3 14 leaks 3 14 orifice 3 14 refrigerant 3 16 removal and replacement 3 19 troubleshooting 3 13 tubing 3 13 refrigerator door 3 2 overview 3 1 parts 3 1 refrigeration module 3 9 temperature sensors 3 2 tools and supplies 3 1 3 10 removal replacement 1 13 repairs 1 13 replacement parts list B 1 reports 4 7 reset sampler 1 12 RS 232 1 4 Ss safety intro i 1 13 screws self tapping 1 14 serial communication 3 23 serial data 1 4 serial port connection 4 7 serial tag location A 1 servicing 1 13 software reset 1 12 updates 1 11 version 1 12 4 11 specifications 1 2 system IDs 1 12 T technical specifications 1 2 temperature sensors 3 2 cable kit 3 3 CPU electronics 3 7 refrigeration 3 3 removal 3 3 sample compartment 3 7 testing cool down 3 23 CPU board 4 7 diagnostic routines 5 1 Index 2 functional tests 4 7 test points 4 6 time and date 4 7 troubleshooting 5 1 Ww wetted parts 1 10
69. d out through the hole in the mounting plate Figure 4 17 Figure 4 17 Removing the line cord from the mounting plate 4 24 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 4 6 2 Line Cord 1 Feed the new line cord through the front of the mounting Replacement plate and tighten the black plastic nut onto the bulkhead fitting until both are flush against the plate The bulkhead fitting has a rubber ring that seals the box and prevents the fitting from coming loose 2 Attach the ground wire to the mounting plate with the lock nut and attach the blue and brown wires to their respec tive terminals Figure 4 16 M Note Before connecting route these wires under those of the com pressor cord as shown in Figure 4 16 to prevent them from being caught under the edge of the protective cover 3 Ensure that the gasket in the cover is evenly seated in its groove Align the cover over the eight mounting holes and reattach it with the self tapping torx screws A CAUTION When reinstalling all self tapping screws avoid destroying the plastic threads First seat each screw in its hole and without pressing down rotate the screw counter clockwise until it falls into its thread groove with a click Then tighten the screw 4 Reinstall the power supply following the instructions in Section 4 5 3 5 Close the rear compartment see Section 1 8 Closing the Rear Compartment 5800 Refrigerated Sampler Ser
70. de Section 2 Sample Delivery System Tubing grooves keep clean Remove hold down panels 2 Peel up A fluoroglas barrier Apply silicone sealant Piezo film detector Figure 2 19 Removing the detector protective barrier 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2 4 Optional Heater The heater prevents liquid from freezing inside the pump under 68 4700 104 115V Only extremely cold conditions M Note The heater prevents liquid from freezing only inside the pump housing cover In extremely cold climates you must also route the suction line correctly to prevent liquid from freezing in the suction line The suction line must have a continuous slope Do not allow loops or low spots in the line where liquid can remain between samples This general practice applies to all climates to prevent sample cross contamination Tools and Supplies e Heater Installation Kit e 2 Phillips screwdriver e Hack saw e Fine sand paper or file 2 4 1 Installation The Heater Installation Kit contains a heater a heat shield self tapping screws and a clip to secure the AC line cord To install the kit 1 Refer to Figure 2 20 and cut a notch in the pump cover with a hack saw or similar tool Use sand paper or a file to remove burrs and smooth the cut edge Figure 2 20 Cut a notch in the top cover for the AC line cord to pass through 2 Fit the heat shield inside the pump cover
71. duction and General Maintenance Table 1 3 Replacement Pump Tubes Part Number Quantity 60 9004 157 1 68 6700 062 68 6700 044 68 6700 045 Example Resetting the Pump Tube Alarm From the Main Menu screen select CONFIGURE 5 You can modify the pump tube alarm setting to tailor it to your needs The factory default setting is PROGRAM CONFIGURE 1 000 000 pump counts However you may VIEW LOG experience tube wear more or less frequently Change the pump count alarm setting by typing the Step through the Configure options until you see first two digits of the new setting The sampler the TUBING LIFE display Press Enter accepts entries between 1 and 99 For example to increase the count to 1 500 000 enter 15 SELECT OPTION lt gt TORMES EEE 00000 PUMP COUNTS TO WARNING The sampler briefly displays the current pump count information Line one lists the pump counts A pump tube alarm should be set to notify you when since the last reset Line two lists the current alarm the pump tube should be replaced A pump tube setting The screen will advance automatically should be replaced when it begins to show signs of wear long before the tube wall fails For more PUMP COUNTS information refer to section 1 4 1 WARNING AT __00000 To reset the counter to zero select YES Always reset the counter after replacing a pump tube Select NO when merely checking the current count RESET PUMP COUNTER YES
72. e sampler displays the test results If the sampler reports ROM FAILED contact your authorized Isco service facility or the Teledyne Isco factory English language only samplers do not include the known value For these samplers the test will report NO CHECKSUM This result does not indicate a pass or fail state only that the ROM test is not valid for this particular sampler The TEST DISPLAY diagnostic tests the sampler s LCD display It cycles blocks of pixels on and off then displays characters on the screen There is no pass or fail message The technician must watch the display to determine if it is faulty To run the test 1 Select the TEST DISPLAY option and press Enter 2 The sampler marches solid boxes across the display fol lowed by characters Observe the display Evidence of a faulty display may include pixels that never turn on pixels that always stay on garbled text 5 1 4 Test Keypad SELECT DIAG lt gt TEST KEYPAD PRESS ANY KEY WATCH DISPLAY ENTER 5 1 5 Test Pump SELECT DIAG lt gt TEST PUMP PUMPING PUMPING ON OFF RATIO PURGING PURGING ON OFF RATIO 5800 Refrigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics poor contrast If any of these or other faulty display conditions exist contact your authorized Isco service facility or the Teledyne Isco factory The TEST KEYPAD diagnostic test
73. e strips Permagum sealant power cables 1 17 1 11 Rear view of refrigeration module Adhesive strip Permagum sealant 1 18 1 12 Slide refrigeration module into place 0 cece eee eee 1 18 1 13 Secure AC Line Cord Full length of line cord not depicted 1 19 2 1 D800 PUMP sce Sei wih Wierd cen aes a hehe bora ap thst ie enc tad eee eA 2 2 2 2 Pump module removal and replacement 0 0 0 cece ee eee eee eens 2 3 2 3 Pump board connections 0 eee nee n eee 2 4 2 4 Installing the pump module 0 cece teen eens 2 4 2 5 Factory test port screw do not remove 00 eee eee ee eee eee nee 2 5 2 6 Thumb screw removal 0 ccc cece eee eee e eee 2 6 2 7 Opening the pump housing cover and latch 0 0 cece eee eee eee 2 7 2 8 Top cover bushing 0 ccc eee e ene r h 2 8 2 9 Pump band removal 0 ccc cece tenet nee 2 8 2 10 Pump band latch arkan sear a it Goal Beta We eave p 2 9 vii 5800 Refrigerated Sampler Service Guide Table of Contents viii 2 11 Optical disk and sensor removal 0 cece cece een eee eens 2 9 2 12 Removing pump motor assembly 0 0 0 e eee eee eee eee 2 10 2 13 Idler and drive gears ars eN ES eea E e a PR 2 10 2 14 Pump motor plate 0 cette tenes 2 11 2 15 Pump motor wiring harness 0 cece eee eee ence eens 2 12 2 16 Pump rotor and hardware
74. eaning the Pump Housing 0 0 cece eee eee 1 10 1 4 5 Cleaning or Replacing Wetted Parts 0 0 c cece e eee eee 1 10 1 4 6 Refrigerator Cleaning Guidelines 0 0 cece eee eee 1 11 Lb Softwares bids awe gaa eet wae eee as A ea baa ne Ga neha ee eee a 1 11 1 5 1 Updating the Software 0 0 ccc ete 1 11 1 5 2 Software Reset roun o Conn ds E 1 12 1 5 3 System IDs 0 da 1 12 1 6 Major Assembly Removal and Replacement 000 cece eens 1 13 1 6 1 Removing a Module 0 0 annaran 1 13 1 6 2 Replacing a Module 0 0 ccc e tenes 1 13 1 6 3 Safety Precautions 0 cette tenes 1 13 1 6 4 Module Reassembly 0 0 0 eee tenes 1 14 1 7 Accessing the Rear Components 000 c ccc eee eee nee 1 15 1 8 Closing the Rear Compartment 20 0 ccc rneer 1 17 Section 2 Sample Delivery System 2A PUMP ceisia Sia HA EAS AO 2 1 2 2 Pump Module Replacement 0 c cece cet eens 2 2 2 2 1 Pump Tubing Removal 0 c cece eee eens 2 3 2 2 2 Pump Module Removal 0 0 0 0 cece ee een nee 2 3 2 2 3 Pump Module Installation 0 00 cc eens 2 3 2 3 Pump Disassembly and Parts Replacement 0 00 c cence eens 2 6 2 3 1 Pump Part Numbers EREE cece NR a Ra E 2 6 2 3 2 Thumb Screw iio ages 8 io oe a ne cee hae oe da Se ew eae e 2 6 2 3 3 Pump Housing Cover and Band 0 0 ce cece eects 2 7 2 3 4 Optical D
75. ection 4 CPU and Power Supply Each test is independently accessed by sending a command starting with T and then a two digit number so that tests do not have to be done in a particular order and can be skipped or repeated When each test is done a string is returned to indicate the results These strings will typically return OK if the test passed and NOT_OK if the test failed In some cases OK will be returned to indicate the end of the test even though the software cannot determine the results of the test as in the display test Table 4 2 provides an explanation of each functional test For wiring diagrams refer to the figures in Appendix A To exit the test mode type Q lt CR gt Remote menu access time out will also exit the test mode Table 4 2 CPU Board Functional Tests Function Command Results Inputs Communication Interface Test serial port TO1 Returns SERIAL PORT OK Calibrate analog input T04 Returns the number of counts for this at 4mA Apply 4mA to pins 8 and 9 of connector current then OK to indicate completion P13 before entering this command see The calibrated value will be saved in flash Appendix A memory when you enter the save command T99 at the end of the test sequence Calibrate analog input T09 Returns the number of counts for this at 9mA Apply 9mA to pins 8 and 9 of connector current then OK to indicate completion P13 before entering this command The calibrated value w
76. een connected to AC power for at least 30 minutes the PCB temperature should be greater than the ambient temperature To display the PCB temperature 1 Select the PCB TEMPERATURE option and press Enter 2 The display shows the temperature until you press the Stop or Enter button If you suspect that the internal heater is not working contact your authorized Isco service facility or the Teledyne Isco factory The INPUT VOLTAGE diagnostic displays the Main CPU board s DC voltage supplied by the power module When this test is started the sampler will display the input power until you press the Stop or Enter button To display the input voltage 1 Select the INPUT VOLTAGE option and press Enter 2 The display shows the voltage The normal voltage range is between 12 3 and 12 7 VDC If the voltage is outside of this range the power supply module is suspect Contact your authorized Isco service facility or the Teledyne Isco factory for further troubleshooting assistance The Main CPU board has an internal battery that provides back up power for the sampler memory while the system is not powered The battery life is typically longer than five years The BATTERY VOLTAGE diagnostic displays no load DC voltage supplied by the internal battery When this test is started the sampler will display the voltage until you press the Stop or Enter button To display the no load battery voltage 1 Select the BATTERY VOLTAGE option and press En
77. efrigerator Figure 2 24 Distributor arm A and discharge tube B 4 Remove the six mounting screws see Figure 2 25 5 Pull the module away from the refrigerator body The wires will slide out through the hole 2 19 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Figure 2 25 Distributor module removal 6 Clean the distributor module s mounting surface inside the refrigerated compartment This will help ensure that the gasket on the new module will seal to the enclosure 7 Feed the wires from the replacement distributor through the hole to the control panel compartment 8 Align the distributor module over the mounting holes and secure it with the mounting screws Torque screws 16 to 18 in lbs 9 Attach the connectors P11 and P14 to the control panel 10 Align the control panel module over the mounting holes and secure it with the mounting screws Torque screws 16 to 18 in lbs 11 Align the key in the distributor arm with the notch in the distributor shaft The arm should seat fully onto the shaft as shown in Figure 2 24 using only slight pressure Reinstall the knurled nut and hand tighten Do not over tighten 12 Install the discharge tube into the arm and connect the end to the bulkhead fitting 13 Perform a distributor diagnostic test Section 5 1 6 2 20 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery
78. electronics that can be damaged by a discharge of static electricity Avoid touching the internal components Only handle the module by the edges or exterior surfaces N CAUTION Electrical connectors and wires can be damaged if improperly handled Electrical connectors must only be handled by the connector body Never grasp the wires or use tools to discon nect a connector Never allow a module to hang by its wiring A CAUTION Earth ground bonding conductor Do not remove or disconnect If this conductor must be disconnected to remove a module it must be reconnected when installing the replacement module Before installing operating or maintaining this equipment it is location and application take heed in the following general warnings N WARNING This instrument has not been certified for use in hazardous locations as defined by the National Electrical Code Isco 5800 Refrigerated Sampler Service Guide Safety N WARNING Avoid hazardous practices If you use this instrument in any way not specified in this manual the protection provided by the instrument may be impaired this will increase your risk of injury Additional safety information can be found in Appendix B Hazard Severity Levels This manual applies Hazard Severity Levels to the safety alerts These three levels are described in the sample alerts below A CAUTION Cautions identify a potential hazard which if not avoided may result in
79. elt around the shaft gear as shown in Figure 2 30 M Note When replacing the timing belt ensure that the belt s teeth are evenly engaged with those of the shaft gear Notice the natural gaps formed when the belt is first installed refer to Figure 2 30 The elimination of these gaps is explained in Steps 4 and 5 Figure 2 30 Improperly positioned timing belt 2 24 Figure 2 31 Installing the cover plate Figure 2 32 Timing belt alignment 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Place the stepper motor on the chassis without tightening the mounting screws ensuring that the belt is around the motor gear Place the cover plate on top of the shaft and reattach with the three large self tapping screws While maintaining the belt tension by pressing the motor away from the distributor shaft slowly turn the large gear until you feel the belt jerk as the teeth fall into alignment Figure 2 32 Turn the large gear at least one full revolution to ensure that all teeth have engaged between the pulley and the belt This eliminates the gaps shown in Figure 2 30 Still pressing back on the motor tighten the two motor plate mounting screws 2 25 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2 8 4 Optical Sensor 1 Slide the optical sensor into place to position it with the optical disk between its upper and lower arms The disk should never touc
80. emperature in degrees C on a new line Display PCB T34 Returns OK to indicate completion temperature This test reads the temperature from the on board temperature sensor and returns this value in degrees C Display compressor T50 Returns duty cycle as a percent of ON time duty cycle for the compressor over the last 4 hours The duty cycle is computed from the state of the Returns OK to indicate completion compressor this data is stored at one minute intervals Power Display input voltage T35 Returns OK to indicate completion This test measures and returns the nominal 12V input voltage to the board Additional input power testing Reduce power input at P10 Power Fail alert measured at TP7 Goes low when 12V power to board falls to about 8 volts Measure the current draw of the board from the 12V supply Power In at U11 Measure the 5V power at W18 to DGND W17 Measure the 3 3V power at P5 1 to DGND W17 Measure the 3 3VA power at W9 to AGND W10 Display battery T36 Returns OK to indicate completion voltage This test measures and returns the voltage of the lithium battery Display loaded battery T37 Returns the battery voltage at one second voltage intervals for 15 seconds This test measures and returns the voltage of Returns OK to indicate completion the lithium battery with the 20K resistor loading the battery Additional battery testing Measure the stand
81. eplacement Parts List 15V PARTS 230V PARTS B 24 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List 605802010 REPLACEMENT PARTS LIST SHEET 24 OF 30 TELEDYNE ISCO REV D DATE PART UMBER DESCRIPTION 604 1002 P amp RELAY POTTING BOX ISV 210 0206 ERLOAD 13 9 AMPS 604 1004 P amp RELAY POTTING BOX 230V 21000 208 ERLOAD 6 8 AMPS 21000 201 ER 21000 209 ER 2329 NUT 46 32 SST W NYLON INSERT 604703 CAP amp RELA ADAPTER PLATE 2313 Ad MA HINE SCREW 6 32 X 7 16 PH SST 21000 TERMINAL BOX 2330108 FLAT WASHER 6 SST NOTE For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 25 Y 3 3 Y S Pw 5 2 Y A 5 amp ES TA 3 n S 2 3 Y oF ER Y Re AQ Ss Y ws Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List 605802010 REPLACEMENT PARTS LIST SHEET 26 OF 30 TELEDYNE ISCO REV D DATE PART NUMBER DESCRIPTION 231611620 SCREW SELF TAP 14 X LONG SST 604703047 INSULATION PANEL 004103063 INSULATION COVER 604703081 COVER BRACE
82. equipped with a three prong grounding plug designed to mate with a grounded power outlet Grounding minimizes the possibility of electrical shock It is the user s responsibility to ensure that the AC power source is properly grounded If in doubt have the outlet checked by a qualified electrician If the available AC power outlet only accepts two prongs or if it is determined that the outlet is improperly grounded the outlet must be replaced by a qualified electrician before attempting to power this device A Ay WARNING If this device s AC power cord is frayed or otherwise damaged discontinue its use immediately Never modify the power cord A replacement power cord is available from Teledyne Isco see Section 4 6 of this manual for more information Isco 5800 Refrigerated Sampler Service Guide Safety Servicing Modules General Warnings Before attempting to remove and replace a module observe the following precautions A Ay WARNING Removing a module exposes you to electrical and mechanical hazards Always disconnect the AC power cord before attempting to remove any module Only trained service personnel may remove or replace these modules N CAUTION Removing the sealed modules will expose the internal compo nents Wet or corrosive atmospheres may attack the exposed refrigerator components Always service modules in a dry cor rosion free environment AN CAUTION Modules contain circuit boards and sensitive
83. er corners in followed by the rest of the gas ket Figure 2 17 Proper installation of pump gasket M Note Installing the gasket without following these steps will result in uneven distribution of the gasket as shown in Figure 2 18 This will result in moisture liquids entering the motor housing leading in turn to internal damage to the pump module 2 13 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Figure 2 18 Improper installation of pump gasket 2 14 2 3 9 Detector Protective Barrier Barrier removal and replacement The liquid detector s protective fluoroglass barrier Figure 2 19 can be removed for cleaning or replacement It is anchored by a hold down panel on either side M Note The piezo film liquid detector is permanently attached to the pump base If it is damaged the entire pump base must be replaced 1 Remove the four self tapping Phillips screws attaching the hold down panels and pull them off 2 Peel the barrier away from the detector 3 Apply a thin layer of 737 RTV sealant 800 1002 03 to the outer edges of the mounting surface taking care to avoid getting any in the tubing grooves 4 Install the new barrier fitting the four inside holes over the insert guides as shown in Figure 2 19 5 Reattach the two hold down panels pressing them down over the insert guides Torque the self tapping screws to 7 10 in lbs 5800 Refrigerated Sampler Service Gui
84. erated by the piezoelectric film liquid detector comes in on P2 Op amp U10 acts as a high impedance load for the detector and buffers the signal delivered to the discrete mul tistage RC filter This filter removes the higher frequency compo nents of the signal U4 A is a buffer after the filter U4 B and the diode on its output rectify the AC signal to a positive DC signal that goes to an a to d input on the CPU U12 measures the temperature in the electronics compartment and outputs a voltage proportional to the temperature This voltage goes into one of the a to d inputs on the CPU The refrigeration air temperature sensor which is an NTC thermistor connects to P3 It is fed a constant voltage of 2 5 volts as Vref The voltage appearing across resistor R36 6 26K goes into one of the a to d inputs on the CPU This is a non linear function so the software must linearize and compute the temper ature The evaporator temperature sensor circuit is identical to the air temperature circuit The sensor also connects through P3 U18 is a supervision circuit It monitors the 12 volt power on pin PFI When this pin gets down to 1 3 volts the power fail output goes to the CPU to start the power down sequence This is when the 12 volt supply falls to about 8 volts Also when the 3 3V supply falls to 2 9 volts this chip issues the Reset signal that stops the processor This chip also does the switchover to battery power for the RAM when the 3
85. ervice Guide Appendix B Replacement Parts List REPLACEMENT PARTS LIST SHEET 12 OF 30 TELEDYNE ISCO REV D DATE PART NUMBER SCRIPTION 231014112 EW MACHINE 0 30 X 3 4 SST 231310310 EW SELF TAP D 8 X 5 8 LONG SST 232916101 lt T LOCK 10 3 ri NYLON INSERT SST 03218 U cS P HOUS G BE AR NG 170301 Co m TECTOR TOP 1103026 ES GE P ET ECTOR COVER 03027 For BES GE P UM P BAND 4024 U E P PA D EM BLY 4032 PLACE CNT D BAND ASSEMBLY 36 PLACEMENT CLUDE P COVER WITH CAUTION LABEL EM 3 1 4031 OU eu a SI PLACEMENT FLUOROGLASS HOLD DOWN KIT 414 y P BASE WIT P EZO W O PUMP PADDLE ASSY 004704035 EPLACEME CLUDES ITE NTT UMB SCREW 4 202500007 RING 1451D X 070 CROSS SECTION NOTE For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 13 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List PUMP A EXPLODE VIEW 2 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List 605802010 REPLACEMENT PARTS LIST SHEET 14 OF 30
86. es and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 37 ice Guide Isco 5800 Refrigerated Sampler Serv Appendix B Replacement Parts List B 38 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List REPLACEMENT PARTS LIST SHEET 8 OF 14 TELEDYNE ISCO REV DATE 082107 Pi PART NUMBER DESCRIPTION 2 1 2 GALLON GLASS BOTTLE WITH CAP amp BALE INCLUDES ITEM 14 BALE NOT SHOWN 4 603004193 LID AND LINER ASSEMBLY 5 6047 03076 4 BOTTLE ADAPTER NOTE For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 39 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List B 40 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List REPLACEMENT PARTS LIST SHEET 10 OF 14 TELEDYNE ISCO REV DATE 082107 ie PART NUMBER DESCRIPTION 299001303 BOTTLE CAP 299001306 5 5 GALLON NALGEN BOTTLE INCLUDES ITEM 4 601623021 LID MODIFICATION ITEM 4 WITH 3 4 DIA HOLE NOTE For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice
87. frigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics 5 6 5 1 7 Test Flow Meter Port SELECT DIAG lt gt TEST FLOWMETER PORT INSTALL TEST PLUG PRESS J WHEN READY FLOWMETER PORT TEST TESTING 5 1 8 Refrig Temperature SELECT DIAG lt gt REFRIG TEMPERATURE REFRIG TEMPERATURE AIR __C EVAP __C The TEST FLOWMETER PORT diagnostic tests the sampler s ability to send event marks and receive an enable pin signal and flow pacing pulses This diagnostic routine is not for field use This test requires a test plug which is inserted into the External Device connector If you have checked all the connections with the external flow meter and still suspect a fault with the event mark or flow pacing signals contact your authorized Isco service facility or the Teledyne Isco factory They will be able to assist you with obtaining a test plug or making the necessary jumper connec tions to run the test To run the test 1 Select the TEST FLOWMETER PORT option and press Enter 2 Insert a Flow Meter Port Test Plug into the Flow Meter connector 3 The sampler tests the send and receive circuits for the event marks sampler enable pin inhibit and flow pulses If the sampler displays FAILED EM gt FP or FAILED INHIBIT verify that test plug is correctly inserted Then perform the TEST FLOWMETER PORT diagnostic again from step 1 If the test still fai
88. gerator 1 11 sampler 1 11 wetted parts 1 10 communication 3 23 compressor 100V 115V 3 20 230V 3 21 charging 3 16 connecting external devices 1 4 contact Teledyne Isco 1 1 B 1 control panel 4 11 cool down test 3 23 D date and time 4 7 diagnostics 5 1 diagrams A 1 distributor 2 18 alignment 5 4 belt and motor 2 24 components 2 21 gasket 2 22 module replacement 2 19 optics 2 26 part numbers 2 26 rebuilding 2 22 shaft 2 23 door 3 2 E electrical system diagrams A 1 electronics control panel 4 11 CPU board tests 4 7 CPU circuit board description 4 1 test points 4 6 F fan 3 17 fuse 4 20 H hardware version 1 12 heater 2 16 I VO 1 4 L line cord 4 22 liquid detector 2 14 M module replacement 1 13 P parts B 1 distributor 2 26 pump 2 6 refrigerator 3 1 power 1 2 power backup 4 14 power supply 4 15 fuse 4 20 line cord 4 22 removal 4 15 replacement 4 20 pump 2 1 cleaning 1 9 components 1 6 gasket 2 13 heater 2 16 housing cover and band 2 7 inspection 1 5 liquid detector 2 14 module replacement 2 2 2 6 motor 2 10 2 11 optics 2 9 part numbers 2 6 rotor 1 7 2 12 servicing 2 6 specifications 1 2 thumb screw 2 6 tube alarm 1 9 Index 1 5800 Refrigerated Sampler Service Guide Index tubing replacement 1 7 wetted parts 1 10 rear compartment closing 1 17 opening 1 15 refrigerant 3 16 refrigeration module
89. great care as it is possible to strip the plastic threads This screw should always be the last to install Figure 2 7 Opening the pump housing cover and latch A CAUTION When reinstalling all self tapping screws avoid destroying the plastic threads First seat each screw in its hole and without pressing down rotate the screw counter clockwise until it falls into its thread groove with a click Then tighten the screw This precaution is not necessary with new unthreaded holes Tighten the screws to 20 28 in lbs Plastic bushing To remove the black plastic bushing in the cover push it out with your thumb from the top Figure 2 8 When replacing this bushing align the key in the bushing with the groove in the cover Figure 2 7 Press the bushing into the bottom side of the cover until it is flush against the cover 2 7 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Bushing Figure 2 8 Top cover bushing Pump band Once the latch is open and the top cover removed the metal pump band simply lifts away from the hinge pin The magnet housed within the band is not removable a Hinge pin ___ Figure 2 9 Pump band removal Latch To replace the pump band latch first unlatch it and open the pump band The latch is attached to the base with two self tapping screws When replacing the latch tighten the mounting screws to 7 10 in lbs 2 8 5800 Refrigerated Sampler Service Guide
90. h the sensor 2 Attach the sensor and plate with the two self tapping mounting screws Tighten the screws to 10 14 in lbs mounting screws 2 Figure 2 33 Installing the optical sensor 2 8 5 Distributor Parts List Table 2 2 contains a list of distributor components and part numbers Table 2 2 Distributor Parts List Band Gasket 60 3113 029 Index Disk 69 4703 018 Motor Pulley Assembly 60 4708 010 Motor Mount Accessory Kit 60 4709 002 Optical Sensor amp Harness 69 4704 026 Sensor Accessory Kit 60 4709 001 Distributor Base 60 4703 014 2 26 5800 Refrigerated Sampler Service Guide Section 3 3 1 Overview 3 1 1 Tools 3 1 2 Parts Refrigeration System This section contains the following service information regarding the 5800 refrigeration system e Temperature Sensors page 3 2 e Refrigeration Module page 3 9 e Refrigeration Cool Down Test page 3 23 Only trained licensed personnel may service the refrigeration module Before performing any of the steps in this section care fully review the important information in Sections 1 6 Major Assembly Removal and Replacement 1 7 Accessing the Rear Components and 1 8 Closing the Rear Compartment Tools required for refrigeration system servicing include 2 Phillips screwdriver 3 Phillips screwdriver wire cutters 15 16 open end wrench clear silicone sealant Additional tools and supplies specific to troubleshooting and ser vi
91. hange without notice B 33 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List C 0 AD 0 WT UT lt JU B 34 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List REPLACEMENT PARTS LIST SHEET 4 OF 14 TELEDYNE ISCO REV DATE 082107 PART NUMBER DESCRIPTIO 299048406 CAP WITH TEFLON LINER 48 0 601683132 GLASS BOTTLE 2100 2700 2 602124020 EXPANDER ASSEMBLY GLASS BOTTLE 6 604704022 BOTTLE RAC BOTTLE RACK ASSEMBLY 350 MILLILITER ec 904104043 INCLUDES ITEMS 7 10 12 amp 16 U NOTE l For current prices and quotations on parts contact Isco Service Department 2 This list is subject to change without notice B 35 ice Guide 5800 Refrigerated Sampler Serv Appendix B Replacement Parts List Isco B 36 Isco 5800 Refrigerated Sampler Service Guide Appendix B Replacement Parts List 604102065 REPLACEMENT PARTS LIST SHEET 6 OF 14 TELEDYNE ISCO REV DATE 082107 PART NUMBER DESCRIPTION BOTTLE CAP 5 299001304 BOTTLE 2 5 GALLON NALGENE INCLUDES ITEM 4 4 BOTTLE ADAPTER NOTE I For current pric
92. harge tube B and stop C 0 00 e ee eee 5 4 5 2 Distributor arm positioning discharge tube removed 5 5 A 1 Location of serial tag 2 0 0 occ RE EKE re rs A 1 A 2 5800 wiring diagram 115V 0 cee eens A 3 A 3 5800 wiring diagram 230V 0 cece eee een eee A 4 A 4 5800 CPU schematic diagram 0 ccc ccc cee ene A 5 List of Tables 1 1 5800 Technical Specifications 0 0 cece ete 1 2 1 2 Unterminated Connect Cable 0 ccc ete 1 4 1 3 Replacement Pump Tubes 0 0 0 cece ect nen eens 1 9 2 1 Pump Parts List A Be BER ee A oS 2 6 2 2 Distributor Parts Liste scons obi is Seen Rl 2 26 3 1 Replacement Parts for 5800 Refrigerator 0 cece eee 3 1 3 2 Refrigeration System Troubleshooting 0 0 cece cence 3 10 4 1 Test Point Functions and Values 0 ccc cece ete eens 4 6 4 2 CPU Board Functional Tests 0 ccc cee ee eee eee 4 8 4 3 Control Panel Identification and Wiring 0 0 ees 4 14 5800 Refrigerated Sampler Service Guide Table of Contents 5800 Refrigerated Sampler Service Guide a se aes a 4 Section 1 Introduction and General Maintenance 1 1 About this Manual Teledyne Isco 4700 Superior St Lincoln NE 68504 Phone 800 228 4373 or 402 464 0231 Fax 402 465 3001 E mail IscoService teledyne com This manual contains servicing information for the model 5800 ind
93. hat all adhesive and Permagum sealants are properly placed on and behind refrigeration module See Figures 1 10 and 1 11 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System Table 3 2 Refrigeration System Troubleshooting Continued Symptom Cause Action Inspect the door gasket and the cork Air leak tape insulation on the compressor suc i tion line Poor performance even if running normally Sampler sitting in direct sunlight or in high ambient temperatures Improve the installation conditions if pos sible High ambient humidity Clanging fan Straighten blades by hand clear out Blades bent or blocked by debris debris secure mounting hardware Fan not running Fan motor failure Replace fan 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System 3 4 2 Inspection 1 Using saddle tap tools Figure 3 9 place pressure gauges on both service ports Figure 3 8 Service Port high pressure Service Port low pressure Figure 3 8 Refrigeration service ports Figure 3 9 Piercing service port 312 O D tubing with a saddle tap tool 2 Reconnect line power and allow the refrigerator to run observing the pressure gauges Pressure on the high port should be around 150 psi pressure on the low port should be around 10 psi A CAUTION All exposed copper tubing MUST be coated with acrylic paint and then covered with shrink tubing to prevent co
94. i Bit nd ma HE po ms a i i moza i i 7 P lem i t Raz i H 2a 20KWV 70UF rr cae waste 2 2 Sam de rol i D voor Ss i cso i 3 3vA Wau DETECT y ns xour es ss ry i a i Mast BATTERY VOLTAGE 124 x 3pF SOV C44 K E i ht xa 7 aL Re gy c bev 7 onze Tavuciotoa i i ura INPUT VOLTAGE TEE VAD xours2 PT ml 1s 000une to woo Le cos vas 74VHCIOTOS w mb t msz52528 jon t i dl Las bal Fr ex 50v at nats Puwe_nev 1 RsS s i i at PETE me i i CONTRAST VOLTAGE Dao F CRIS i 1 t 2_rewpenarune CON AST VOKT BON purre 198 ser sov k 1 2 bh i i R73 1 En i ess S sa Ras NDA ONDBU cnoe on o o EISOND vaias A k asses dl Tat Tov i cas 5 sono A AS PA reverse E 4 a a 100K TND seno R71 100K EY Push t i Bov sov pov apr teow ESA a a i va 32 76skuz TEEN 5 mo H To i css css ess rss ee PwRGNO VFB i 100009r A r Tok Wk y me A i 21 pep LLEVAPORATOR_TEMPERATURE Sov Tao T r oor sov ao 113433 a K i 5 Y Bov TEMPERATURE R29 D TCK lol za P db O O O Ya ud AX 25PPM or TOO rs a0 al P3 2 VREF GND RESET ea a 10000pF 3 3v qe sayy wi P34 i 2 ras 1 S Toae ee aa 3 en1 cas cao c79 cra e77 a 057 647 F o la ly le le le e la 3 z 3 3 3 B E EN ar S58 F129F 120 apr 129F tap f a 2s 8 Z 8 8 8 5 JE E E 3 E z JE 1252323 125 20e 120F 129F 120129 i a E JE E 8 2 JE 5 8 5 5 5 5 5 5 Sy S 1 a a Sar sov sov sov sov sov sov i sov sov Ya E JE JE 5 E a
95. iate diagnostic tests in Section 5 1 There are several precautions you should observe before attempting to remove and replace a module A AY WARNING Removing a module exposes you to electrical and mechanical hazards Always unplug the AC power cord before attempting to remove any module Only trained service personnel may remove or replace these modules 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance A CAUTION Removing the sealed modules will expose the internal compo nents Wet or corrosive atmospheres may attack the exposed refrigerator components Always service modules in a dry cor rosion free environment A CAUTION Modules contain circuit boards and sensitive electronics that can be damaged by a discharge of static electricity Avoid touching the internal components Only handle the module by the edges or exterior surfaces A CAUTION Electrical connectors and wires can be damaged if improperly handled Electrical connectors must only be handled by the connector body Never grasp the wires or use tools to discon nect a connector Never allow a module to hang by its wiring A CAUTION Earth ground bonding conductor Do not remove or discon nect If this conductor must be disconnected to remove a mod ule it must be reconnected when installing the replacement module 1 6 4 Module Reassembly It may become necessary to service or replace module compo nents When rebuild
96. ill be saved in flash memory when you enter the save command T99 at the end of the test sequence Calibrate analog input T20 Returns the number of counts for this at 20mA Apply 20mA to pins 8 and 9 of connector current then OK to indicate completion P13 before entering this command see The calibrated value will be saved in flash Appendix A memory when you enter the save command T99 at the end of the test sequence Test flow meter input T31 Returns OK or NOT_OK and output flow pulse and event mark This test requires an external connection between the event mark output P12 6 and the flow pulse input P12 4 High and low signals are transmitted from the event mark output Test external interface T32 Returns OK to indicate completion outputs This test takes all 4 external interface outputs low Then each line outputs a 100 ms high signal followed by a 100 ms low signal in the following order P13 2 P13 3 P13 6 and P13 7 The lines are left in the low state 4 8 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Table 4 2 CPU Board Functional Tests Continued Function Command Results Electronics T22 Returns OK or NOT_OK Loads and reads back the four 16 bit words FFFF 0000 a5a5 and 5a5a in RAM T23 Returns OK or NOT_OK Performs a Checksum test Test display T24 Returns OK to indicate completion Solid boxes march across screen then alphabet ch
97. ing To update your sampler s software 1 Visit www isco com or contact the factory to request the update be sent via e mail and click on Software Firmware Updates Service amp Support gt Support gt Schematics gt Software Firmware Updates Terms and Conditions 2 Click on Automatic Water Samplers 5800 Software 3 Click the 5800V exe link and save the zipped file to the location of your choice This zipped file contains two files the 5800 software bin file and a pdf file documenting the history of all 5800 soft ware updates to the present Extract these two files 4 With the 5800 turned on connect it to your computer To connect the sampler to a computer use the optional serial communication cable available with either DB 9 69 5804 042 or USB 60 5804 177 connector To sampler To computer mj Figure 1 5 5800 Sampler to RS 232 serial communication cable 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance 1 5 2 Software Reset 1 5 3 System IDs SELECT OPTION lt gt SYSTEM IDs 5800 Sampler ID SS HARDWARE ___ SOFTWARE _ _ 5 Start Flowlink s application Update Software a From the computer START menu select PROGRAMS and highlight Flowlink b Select Update Software 6 Follow the update instructions in the Update Software Help menu If the 5800 does not appear to be operating normally
98. ing reassembling a module always observe the special instructions provided for each assembly in order to preserve the life and integrity of each component N CAUTION When reinstalling all self tapping screws avoid destroying the plastic threads First seat each screw in its hole and without pressing down rotate the screw counter clockwise until it falls into its thread groove with a click Then tighten the screw This precaution is not necessary with new unthreaded holes 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance Wait for Tclick Figure 1 6 Self tapping screws reinstallation 1 7 Accessing the Rear 1 Unplug the line cord to remove AC power C t omponents ZN WARNING Removing the refrigeration module exposes you to electrical and mechanical hazards Always disconnect from AC power before exposing the refrigeration module Only trained service personnel may access these areas 2 Remove the cover brace back cover and insulation panel Figure 1 7 Refrigeration module Insulation panel Figure 1 7 Remove back cover and insulation 3 Cut the cable tie from the power cord that runs through the refrigeration assembly Figure 1 8 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance Cut cable tie Figure 1 8 Cut cable tie from line cord Full line cord length not depicted 4 Remove the
99. ior to use e 2 amp 3 Phillips screwdrivers e 15 16 open wrench e 1 32 open wrench e Wire cutters Removal replacement of the power supply requires accessing the rear interior of the refrigerator Follow the instructions provided in Section 1 7 Accessing the Rear Components and then do the following 1 Remove the power cord following substeps a b and c a 230 VAC Models Only Remove the AC Plug adapter from the end of the power cord by first cutting away the plastic heat shrink tubing Then pull the adapter off leaving just the North American 115 VAC plug Figure 4 4 4 15 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Figure 4 4 Remove adapter from power cord Figure 4 5 Remove power cord b Slide the bushing sideways away from the refrigeration module until it is free Figure 4 5 Use care to avoid bending the refrigeration tubing thal UL WY TA tt a p y c Pull the power cord through the refrigeration module Remove the electrical cover on the side of the compressor Disconnect the blue and brown wires from the spade con nections on the side of the compressor and the green and yellow ground wire from the module chassis These three wires are from the Power Supply module For 115 VAC systems refer to Figure 4 6 For 230 VAC systems refer to Figure 4 7 Open the top cover of the sampler and remove the control panel mounting screws see Figure 4 8
100. isk amp Sensor 0 0 ccc cette eens 2 9 2 3 5 Pump Motor and Wiring 0 0 ccc tenes 2 10 2 3 6 Motor Replacement 0 e cece cece eens 2 11 Zieh ROTOR isis ace hs A A Gl ake etna ER TE SE ERR 2 12 28 8 Gaskets ee ow es ka eae TA EE oe OS ea 2 13 2 3 9 Detector Protective Barrier 0 cece eee eens 2 14 2 4 Optional Heater nis ii a OR eee Peed ted 2 16 2 4 1 Installations conti Eae aE Sa Ipod adi ti EnG Ee 2 16 2 5 Distributor cs g i0 0 ee A a 2 18 2 6 Distributor Module Replacement 0000s cece ete eens 2 19 5800 Refrigerated Sampler Service Guide Table of Contents vi 2 7 2 8 Disassembling the Distributor 0 0 c cece eens 2 21 Rebuilding the Distributor 0 0 0 0 ccc cence nee 2 22 2 8 1 Gasket oct scadere ein dd we dae da 2 22 2 8 2 Distributor Shaft zesire skake E cette eens 2 23 2 8 3 Belt and Motor 25 055 A the ee Sep ete Wee a oe 2 24 2 8 4 Optical Sensor 00 ated data 2 26 2 8 5 Distributor Parts List 0 0 cee tenes 2 26 Section 3 Refrigeration System 3 1 3 2 3 3 3 4 3 5 OVER View Ad A enes Saale otra Stade wih Sasha E sah ey 3 1 3 LI EAN 3 1 3 L2 A A OS 3 1 Door ii A A A A as ee De TS 3 2 Temperature Sensors o 3 2 3 3 1 Temperature Sensor Cable Assembly oooooooooooooooooo 3 3 3 3 2 CPU Temperature Sensor 0 0 ccc eee ences 3 7 3 3 3 Sample Compartment Thermometer optional
101. ive circuitry refer to Section 4 1 10 For functional CPU board testing through HyperTerminal see Section 4 3 3 Functional Tests The tests are listed by category in Table 4 2 Refer to Section 5 1 6 for standard 5800 distributor diagnostics Test Point 15 located on pin 2 of U40 on the CPU see Figure A 4 in Appendix A gives the home output from the distributor stepper motor driver This signal will be low when both phases are being driven at 70 7 For a complete list of 5800 test points and values refer to Section 4 2 Test points are also highlighted in red on the CPU schematic in Figure A 4 Appendix A 5 16 nut driver 1 and 2 Phillips screwdrivers 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2 6 Distributor Module The distributor module can be replaced as a single unit Replacement 68 4704 029 A A WARNING Risk of injury or equipment damage Familiarize yourself with the general instructions in Section 1 6 before proceeding 1 Remove the mounting screws that secure the control panel see Figure 4 1 2 Disconnect the two distributor cable connectors P11 and P14 see Figure 4 2 3 Remove the distributor arm and discharge tube a Remove the knurled nut that secures the distributor arm and pull the distributor arm downward to disen gage its positioning key from the notch in the shaft b Pull the discharge tube off of the bulkhead fitting in the top front corner of the r
102. l 1 1 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance 1 2 Technical Specifications Table 1 1 contains technical specifications for the 5800 sampler Table 1 1 5800 Technical Specifications Size HxWxD 130 x 72 x 84cm 52 x 29 x 33 in Weight empty 83 5 kg 184 Ib Bottle Configurations 13 configurations available 24 1 liter PP 24 350 ml glass 4 10 liter PE or glass 4 20 liter PE 2 10 liter PE or glass 1 20 liter PE or glass 1 10 liter PE or glass 24 ProPaks 1 liter wedge 1 ProPak 10 liter round Refrigerator Body Linear low density polyethylene LLDPE Power Requirements 115 VAC 10 60 Hz Sampler Running current 4 amperes Stopped current 22 amperes 230 VAC 10 50 Hz Sampler Running current 2 amperes Stopped current 17 amperes Installation Category Pollution Degree 3 Maximum Altitude 2 000 meters 6 562 feet Humidity 0 to 100 Operational Temperature 29 to 49 C 20 to 120 F Pump Intake Suction Tubing Length 1to 30m 3 to 99 feet Material Vinyl or FEP lined polyethylene Suction Line Inside Diameter 3 8 inch 9 mm Pump Tubing Life Maximum Suction Lift Typically 1 000 000 pump counts 8 5m 28 feet Typical Repeatability Ability to repeat the delivered volume for a set of samples collected under the same conditions 5ml
103. ls contact your authorized Isco service facility or the Teledyne Isco factory The REFRIG TEMPERATURE diagnostic displays the temper ature of the refrigerated compartment When this test is started the sampler should display the temperature until you press the Stop or Enter button There is no pass or fail This test simply provides continuous temperature monitoring If the screen displays an asterisk or inaccurate temperature reading the temperature sensor cable may be malfunctioning See Section 3 3 1 for replacement procedures To display the refrigerator temperature 1 Select the REFRIG TEMPERATURE option and press Enter 2 The display shows the temperature until you press the Stop or Enter button 5 1 9 PCB Temperature SELECT DIAG lt gt PCB TEMPERATURE PCB TEMPERATURE 5 1 10 Input Voltage SELECT DIAG lt gt INPUT VOLTAGE INPUT VOLTAGE NM 5 1 11 Battery Voltage SELECT DIAG lt gt BATTERY VOLTAGE BATTERY VOLTAGE AN 5800 Refrigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics The TEST PCB TEMPERATURE diagnostic displays the temper ature of the Main CPU Printed Circuit Board PCB When this test is started the sampler will display the temperature until you press the Stop or Enter button The Main CPU board has a heater that prevents condensation from forming inside the electronics compartment If the sampler has b
104. me position against the front of the stop on the distributor module Figure 5 2 5800 Refrigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics Figure 5 2 Distributor arm positioning discharge tube removed GO TO BOTTLE __ 1 max 4 Press the Calibrate button This saves the current distributor arm position as home M Note The arm must be at the stop when the Calibrate button is pressed The calibrate function always saves the arm s current position as home 5 Enter the bottle number to which the sampler should move the arm Press Enter and the distributor will run MOVING TO BOTTLE ___ NOW AT BOTTLE 6 The sampler reports the new distributor arm position Ver ify that the arm is aligned over the correct bottle GO TO BOTTLE 7 7 The sampler then asks for the next bottle position Enter a 1 max bottle number and press Enter or press the Stop button to exit the test If the sampler displays DISTRIBUTOR JAMMED DISTRIBUTOR ERROR SLOT CODE ERROR DISK ERROR or BELT TOO LOOSE verify that the arm movement is not obstructed Clear any obstructions such as bottles not fully seated in the rack or an incorrectly installed discharge tube then perform the TEST DIS TRIBUTOR diagnostic again from step 1 If you don t find obstruc tions to the distributor arm movement contact your authorized Isco service facility or the Teledyne Isco factory 5 5 5800 Re
105. mended Figure 3 10 Refrigerant dryer before and after installation and coating 3 14 Orifice Refrigerant leaks The precision orifice through which liquid refrigerant changes temperature and pressure before entering the evaporator coil is a very delicate device and is easily clogged It is therefore critical to prevent anything other than refrigerant from entering the system such as solder flux particles water or oxidized copper If the orifice becomes clogged or otherwise damaged replacement of the refrigeration module is recommended due to the likelihood of a new orifice becoming clogged with flux during the brazing process Leaks are most likely to occur in the locations indicated by arrows in Figure 3 11 A leak near the dryer or orifice is likely to be caused by a drastic difference in temperature and pressure on either side of the orifice Other leaks may have been caused during shipping or other physical shock Repair leaks with refrigeration grade copper tubing brazing the ends with silver solder and properly covering all joints and exposed metal from corrosive elements Ay WARNING Do not run the compressor during evacuation leak testing or charging 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System Orifice amp Overload 115V box shown Figure 3 11 Refrigeration module components possible leak areas indicated by arrows AN CAUTION All exposed copper
106. ment du m canisme pr s de ces symboles Warnungen und Vorsichtshinweise Das Ausrufezeichen in Dreieck ist ein Warnzeichen das Sie darauf aufmerksam macht da wichtige Anleitungen zu diesem Handbuch geh ren Der gepfeilte Blitz im Dreieck ist ein Warnzeichen das Sei vor gef hrlichen Spannungen im Inneren des Produkts warnt Vorsicht Quetschgefahr Dieses Symbol warnt vor einer unmittelbar dro henden Verletzungsgefahr f r Finger und H nde wenn diese zwischen die beweglichen Teile des gekennzeichneten Ger tes geraten Advertencias y Precauciones Esta se al le advierte sobre la importancia de las instrucciones del manual que acompa an a este producto A AN Esta se al alerta sobre la presencia de alto voltaje en el interior del pro ducto AN Punto del machacamiento Sus dedos o manos seriusly ser n da ados si usted los coloca entre las piezas m viles cerca de estos s mbolos 5800 Refrigerated Sampler Service Guide Table of Contents Section 1 Introduction and General Maintenance 1 1 About this Manual ssis reres ce va deton a neg 1 1 1 2 Technical Specifications 0 0 0 eneret 1 2 1 3 Connection to Other Devices 0 00 eee eens 1 4 1 4 General Maintenance 0 cece eee e nent n nee 1 5 DAD PU a 2 1 A PEAR A S 1 5 1 4 2 Pump Tube Replacement 0 0 cece teens 1 7 1 4 3 Cleaning the Pump Rollers 0 0 tenes 1 9 1 4 4 Cl
107. minor or moderate injury This category can also warn you of unsafe practices or conditions that may cause property damage Ay WARNING Warnings identify a potentially hazardous condition which if not avoided could result in death or serious injury DANGER DANGER limited to the most extreme situations to identify an imminent hazard which if not avoided will result in death or serious injury Isco 5800 Refrigerated Sampler Service Guide Safety Hazard Symbols Warnings and Cautions The equipment and this manual use symbols used to warn of hazards The symbols are explained below Hazard Symbols The exclamation point within the triangle is a warning sign alerting you of important instructions in the instrument s technical reference manual The lightning flash and arrowhead within the triangle is a warning sign alert ing you of dangerous voltage inside the product Pinch point These symbols warn you that your fingers or hands will be seri ously injured if you place them between the moving parts of the mechanism near these symbols Symboles de s curit Ce symbole signale l existence d instructions importantes relatives au pro duit dans ce manuel A AN Ce symbole signale la pr sence d un danger d lectocution AN Risque de pincement Ces symboles vous avertit que les mains ou les doigts seront bless s s rieusement si vous les mettez entre les l ments en mouve
108. mounting screws inserting the top three first A CAUTION Ensure that all wires are tucked into the pump module com partment and not caught between the gasket and mounting surface Insert top row of screws first Ensure that wires are not caught under gasket 3 After all six screws are inserted torque the screws 1 8 to 2 0 Nm 16 to 18 in lbs 4 Install the pump tube a Loosen the Liquid Detector Cover F by unscrewing the large black knob H b Unlatch the Pump Housing Band J c Thread the pump tube through the pump Note that the short end inlet should extend from the top open ing 2 4 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System M Note When the hinged portion of the pump module is opened another large screw is revealed Figure 2 5 This is a sealed port used solely for factory testing Do not loosen or remove this screw Blue collars amp alignment notches Test port Do not remove screw Figure 2 5 Factory test port screw do not remove d Align the blue collars with the alignment notches e Close the liquid detector cover and secure it tightly with the knob 5 Reconnect power and perform all diagnostic tests 2 5 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2 3 Pump Disassembly and Parts Replacement 2 3 1 Pump Part Numbers numbers For module removal and replacement steps see Section 2 2
109. mp Tubing Removal Ifthe pump tube will be used in the new pump remove the tube before removing the pump module 1 Disconnect power from the sampler to ensure that it will not attempt to operate the pump 2 Loosen the Liquid Detector Cover F by unscrewing the large black knob H 3 Unlatch the Pump Housing Band J 4 Pull the tube A away from the bulkhead fitting B and disconnect the tubing coupler and suction line 5 Pull the tube out through the pump 2 2 2 Pump Module Removal 1 Beginning with the three bottom screws remove the six mounting screws see Figure 2 2 holding the module in place to avoid pull or strain on the wires 2 Pull the module away from the refrigerator body and dis connect the four wiring connectors Figure 2 2 Pump module removal and replacement 2 2 3 Pump Module Clean the pump module mounting surface on the refrigerator Installation body This will help ensure that the gasket on the new module will seal the enclosure 1 Attach the four wiring connectors from the new pump mod ule to the pump interface board a Yellow gt P3 pump band sensor b Red and black twisted gt P10 pump motor c Red and black gt P8 detector d Red black white green gt P4 optical sensor 2 3 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Figure 2 3 Pump board connections 2 Align the module over the mounting holes and secure it with the
110. mple Volumes 10 to 9 990 ml in 1 ml increments Sample Retries If no sample is detected up to 3 attempts user selectable Rinse Cycles Automatic rinsing of suction line up to 3 rinses for each sample collection Controller Diagnostics Tests for RAM ROM pump display and electrical components Refrigeration Temperature Accuracy 1 C from average temperature over a 48 hour period Bottle configuration 1 X 2 5 gal polyethylene Tested with setpoint 3 C ambi ent temperature 20 C in 30ml glycol bottle located on rack between rear rack locations 3 and 4 see figure below a The maximum altitude rating is per European Norm 61010 1 which establishes safety requirements for electrical equip ment The rating pertains to electrical creepage and clearances The rating is not applicable to pump performance 1 3 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance 1 3 Connection to Other Table 1 2 lists the pin functions of the sampler s rear connector Devices for connection to external devices Figure 1 1 16 pin rear connector Table 1 2 Unterminated Connect Cable Sampler Wire Color Signal Name Input Output Parameters Comments 12 VDC Power Output 14 5 to 12 0 VDC 0 to1 ampere maximum Power for external devices Ground N A Common ground Flow Pulse Input 25 millisecond minimum pulse 5 to 15 VDC Serial Data Output
111. n average rate of at least 0 5 degrees per minute for 20 minutes This test is accessed through the serial port interrogator port with a terminal emulation program such as Tera Term To connect the sampler to a computer use the optional serial communication cable available with either DB 9 69 5804 042 or USB 60 5804 177 connector 1 Configure your communications software for a baud rate no higher than 38 400 8 data bits no parity 1 stop bit No flow control Auto Detect or VT100 terminal emulation 2 Using your communications software connect to the sam pler Repeatedly type Shift using the computer keyboard until the sampler returns its banner string The banner string lists the model number and unique ID of the sampler A gt prompt will appear on the screen when it is ready to accept commands 3 At the prompt enter the command COOL lt CR gt This test sequence takes 20 minutes to complete Following the command it will generally take 1 to 2 min utes for the compressor to start At this time the starting temperatures of the refrigerator and evaporator are sent to the computer along with a header row for four tabular col umns Every minute a row will be added to the table with the run time current temperature difference between the current and start temperature and average rate of change At the end of the test if the rate of change was within the acceptable range the message COOLDOWN T
112. n tube and drip pan ee eee eens 3 21 4 1 Control panel module removal replacement 00 e eee ee eee 4 12 4 2 Control panel wiring connectors 0 cece eee eee eens 4 13 4 3 5800 battery backup module 0 0 cece cette 4 15 4 4 Remove adapter from power cord 00 eee e ee ee eee eee e eee 4 16 4 5 Remove power cord ooo 4 16 4 6 Electrical connections on 115V compressor 00 eee e eee eee eens 4 17 4 7 Electrical connections on 230V compressor 0 0c cece cence eens 4 17 4 8 Control panel removal replacement 0 0c cece eee eee eee 4 17 4 9 Cord grip fitting on refrigerator wall 0 cece eee eee ee 4 18 4 10 Remove fan mounting screws and disconnect cable view from inside refrigerator 0 0 cece tenes 4 19 4 11 Power supply back plate o oooooooooorrrorrrr teens 4 20 5800 Refrigerated Sampler Service Guide Table of Contents 4 12 Fast blow fuse on the new power supply 0 00 ccc e eee eens 4 20 4 13 Secure AC Power cord with bushing and cable tie Full line cord length not depicted 0 0c cece eens 4 21 4 14 230V line cord plug adaptor 0 cette tenes 4 21 4 15 Remove power supply cover 0 0 cece cece enn ene 4 23 4 16 Line cord connections 0 cece eee nen e eee 4 24 4 17 Removing the line cord from the mounting plate 4 24 5 1 Distributor arm A disc
113. ng Refrigerati 322 E efrigeration Bac 3 L 2 Control 00000 P8 Pump Latch 000 12345 1 3 nd i Fun Po Pump Liquid P9 Pump Rotation EE Detector Sensor 0000 1234 s 3 p3 Temperature RER pio Power Blk Sensors e000e0 Controller ds Wht 1 5 O E Distributor F588 P4 Not Used p11 Motor 1 23 4 Door Open Blk External Device P5 SPA only hed pig Interface z 5 a 55 External Device 3927 220 lt P6 Keypad Ribbon Cable P13 oil g si 0000000000 123 6 7 8910 Distribut 2 598 Blk istributor a 23 P7 Pump Motor hey P14 Sensor 1 3 4 5 4 4 4 Power Backup The 5800 is capable of switching the sampler controller to backup 60 5314 696 power from an Isco power supply in the event of AC power loss M Note This provides backup power to the sampler controller only not to the refrigerator To enable power backup connect the module to the 16 pin con nector on the back of the sampler Connect an Isco Lead Acid Battery sold separately to the 2 pin amphenol connector on the module The module duplicates the 16 pin connector to allow con nection to other devices 4 14 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 4 6 pin connector Figure 4 3 5800 battery backup module 4 5 Power Supply 115V 60 4704 165 230V 60 4704 166 4 5 1 Power Supply Removal e Nylon cable tie 489 0110 00 For best results soak in water for one hour pr
114. nt of its sub assemblies This expedites the repair and saves shipping costs These sub assembly modules should be replaced by trained personnel The sub assemblies are e Pump Module Section 2 2 e Distributor Module Section 2 6 e Refrigeration Module Section 3 4 5 e Control Panel Module with Main CPU board Section 4 4 e Power Supply Section 4 5 The removal and replacement instructions include general steps that apply to all modules and detailed instructions for each module Before proceeding with the detailed instructions in the following sections familiarize yourself with these general steps for the removal and replacement of a module Unplug the AC power cord Remove the mounting screws Carefully lift the module away from the refrigerator body A O N e Label the wires with the location of their connection then disconnect the wiring connectors pa Ensure that the gasket seal is in place The gasket surface must be smooth clean and free of nicks cracks etc If any imperfections are visible replace the seal 2 Reconnect the wiring connectors using care to correctly pair the connectors and to correctly align the keys and pins 3 Ensuring that no wires are caught between the module and mounting surface align the module over the mounting holes and secure it with the mounting screws 4 Apply AC power and turn on the sampler 5 After replacement test the new module using the appro pr
115. o le cms le cio 22007 2200 Res o vo oxo he as Zas Sr Tavneror32 wl alu rra ar EM 2200 2200 16v 16V GND 100k lt 100K 100k jas Sel er fs i avr i ba isis per ee SNTALVGCIZASA Fae eL pee Jl asi D soispLay_cs as alin bee S2 OPTION a aw E i SPA ED Gg ao a wowe Yo o Vo o Vo Vo Vo JA BE 285 Jii 27 W30 A2 mri per a a Gy ae 1 INPUT VOLTAGE pE BATTERY VOLTAGE dr EVN D100 151 1 FLOWMETER crt uss Sr Tee ono 1 1M285DR 2 3 cue cts pz H a ee 254 25v A res enol Ll ll a i 10000pF Rat 3 3V 100K E 8530013 100009 3 A 0 hev sv P12 1 2 FLOW_PULSE 33 8L SN74LVCC3245A c pins rue er Y ors Gry pe i D Pi2 5 t ms M m E he ON France 0 i E es 10000pF sie a za Pov MES A F pi ey EN oz mo wo cis Yo 5 7avicroraz i P12 8 ro sp va si 3 10K uso A 2 Is i Gg use Y voog TAE 456 U5 A us JH i me i f casa rss casa cass 1280086 5 a n 5 gt Farre sre ORR os 3 A 2 us i i SBA sweisca suatsa SMBISCA ns HG lout OMA EVENT MARK e a OM_DIRECTION Rey VESES zal Poy Fanc 5 Tavyciotos i cu7 cus cus e150 lout stat Swe 7OM RESET RESET crite F i 330pF 330pF 330pF 330pF 10000pF lout end E e i Sov Sov EN 50V Mapi By Ms2 28 us 8 Yo j mo TE Ne ne ne azcoscis cos En ono p p rua Howe von a EJ i da Yo 7 il i RE 3 3V 10K es ka i Hi Ly Ls CINES Se 10K mep i 3 3VA SPARES i SL SPARE SAV SPARES ser Sune gt i VNO2HSP ge f i i SR SENSEI i 1 de 3 B INHIBIT 1 3 3VA i
116. o to the LCD display The logic for address decoding is built into the CPU so there is no external logic to generate the chip selects to the memories and display Three temperatures 2 voltages and an analog signal from the liquid detector go into the a to d inputs Likewise the serial signals to from the internal UART go to an RS 232 d to a con verter chip Approximately 28 digital I O lines come directly from the CPU Additional I O lines are provided by the I O expanders 4 1 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 4 2 4 1 2 Memory U13 14 4 1 3 I O Ports U26 29 4 1 4 Power Supplies U9 27 28 VR1 P10 4 1 5 Serial Port Ul These chips communicate with the CPU over an SPI bus serial peripheral interface The lines SPCK MOSI and MISO provide the data path for this communication The CPU contains an internal watchdog circuit but this is not being used The CPU has built in RAM for some special functions such as reprogramming the FLASH but is not used for normal oper ation such as storing variables U14 is the flash memory that contains the boot code and appli cation code and the text strings for all languages that may be available It has a capacity of 4 Mb At present the application code is about 180 K which is less than 5 of the total flash U13 is the RAM memory It is static RAM and contains 512 K bytes It is backed up by an on board lithium battery
117. ok for debris buildup on the pump roller or guide surfaces Figure 1 3 Clean when needed Section 1 4 3 c Housing Look for debris inside the pump housing Clean as necessary Section 1 4 4 Debris inside the housing is usually evidence that a pump tube failed AN CAUTION Never use lubricants or solvents on the pump tube or rollers Many chemicals they contain will attack the plastic and sili cone causing irreparable damage to the pump 1 4 2 Pump Tube The correct sampler pump tubing is easily recognized by the blue Replacement alignment collars Pump tubing from non Isco vendors and tubes designed for other types of samplers should not be used Incorrect pump tubing may result in poor pump performance or even cause parts to fail Also note that the discharge tube is not the same as the pump tube Refer to Figure 1 2 and the following steps to replace the pump tube 1 Unplug the sampler to ensure that it will not attempt to operate the pump 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance Ay WARNING The sampler has a safety interlock that prevents the pump from operating when the pump housing band is open DO NOT tamper with the pump housing and band The pump is extremely powerful The pump can injure you severely if the sampler activates the pump while you are working on it Remove power from the sampler before opening the pump housing 2 Loosen the Liquid Detector Cover
118. onents 2 8 1 Gasket Replace the gasket using the following steps as shown in Figure 2 28 1 Always begin by pressing it into one corner of the base 2 2 22 Pull the gasket taut then press the gasket down into the opposite corner This prevents the gasket from being unevenly distributed in the groove ensuring the integrity of the seal Press the other corners in followed by the rest of the gas ket 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Figure 2 28 Distributor gasket replacement M Note Installing the gasket without following these steps will result in uneven distribution of the gasket as shown in Figure 2 18 This will result in moisture liquids entering the motor housing leading in turn to internal damage to the pump module 2 8 2 Distributor Shaft To assemble the distributor shaft refer to Figure 2 29 and do the following 1 Place the disk spacer on the bottom side shaft side of the shaft gear aligning the four pairs of holes 2 Position the index disk so that the notch in the disk is visi ble and aligned with the notch in the distributor shaft Replace the four screws 3 Reinstall the distributor shaft in the brass bearing in the base 2 23 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Disk spacer Figure 2 29 Reassembling the distributor shaft 2 8 3 Belt and Motor To replace the belt and motor 1 Place the timing b
119. oor outdoor refrigerated sampler The manual contains five sections and two appendices Section 1 Introduction and General Maintenance contains safety and technical information about the sampler It also pro vides general information about upkeep and maintenance proce dures for removal replacement of modular components and procedures for opening and closing the refrigerator s rear com partment Section 2 Sample Delivery System contains service and replacement information for the pump and distributor modules and their components Section 3 Refrigeration System provides instructions for trou bleshooting servicing and replacing the temperature sensors and refrigeration system and its components Section 4 CPU and Power Supply contains a detailed description of the CPU board and test points CPU board tests and instructions for removal replacement of the control panel power supply and line cord Section 5 Electrical Troubleshooting and Diagnostics contains diagnostic testing and troubleshooting steps Appendix A Electrical Diagrams contains wiring and com ponent diagrams and an electrical schematic as well as instruc tions for accessing electrical schematics on the Teledyne Isco web site Appendix B Replacement Parts List contains drawings and order numbers for all replaceable parts as well as ordering infor mation Refer to this appendix for complete listings of all replaceable parts described in this manua
120. or 5 of the average volume in a set whichever is greater at lifts up to 25 feet Typical Delivered Volume Accuracy 10ml or 10 of programmed value whichever is greater Typical Line Velocity at Head Height 0 9 m 0 91 m s 3 ft 3 0 ft s 3 1 m 0 87 m s 10 ft 2 9 ft s 4 6 m 0 83 m s 15 ft 2 7 ft s 7 6 m 0 67 m s 25 ft 2 2 ft s 1 2 Approx 300 RPM depending on sampling conditions 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance Table 1 1 5800 Technical Specifications Continued Liquid Presence Detector Non wetted non conductive sensor detects when liquid sample reaches the pump to automatically compensate for changes in head heights Controller Enclosure Rating Program Memory IP67 NEMA 4X 6 Non volatile ROM Flash Flow Meter Signal Inputs 5 to 15 volt DC pulse or 25 millisecond isolated contact closure for Isco flow meters 4 20 mA input for non Isco flow meters Digital Alarms 4 programmable outputs 5 VDC 100 mA Number of Composite Samples Sample Frequency Programmable from 1 to 999 samples 1 minute to 99 hours 59 minutes in 1 minute increments 1 to 9 999 flow pulses Sampling Modes e Constant Time Constant Volume e Variable Time Constant Volume e Constant Time Variable Volume Variable time and variable volume modes are controlled by an external flow meter signal Programmable Sa
121. out each test SELECT DIAG lt gt TEST RAM 5 1 5800 Refrigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics 5 2 5 1 1 Test RAM SELECT DIAG lt gt TEST RAM TESTING RAM RAM PASSED 5 1 2 Test ROM SELECT DIAG lt gt TEST ROM TESTING ROM ROM PASSED 5 1 3 Test Display SELECT DIAG lt gt TEST DISPLAY ABCDEFGHIJKLMNOPQRST ABCDEFGHIJKLMNOPQRST The TEST RAM diagnostic tests the sampler s memory that is used dynamically by the sampler s processor and holds program settings and sample event data This test loads 16 bit words into memory and reads it back to confirm that the memory is working correctly To run the test 1 Select the TEST RAM option and press Enter 2 Wait for the sampler to complete the test 3 When finished the sampler displays the test results If the sampler reports RAM FAILED contact your authorized Isco service facility or the Teledyne Isco factory The TEST ROM diagnostic tests the sampler s Read Only Memory which holds the sampler software It calculates a checksum total of the data held in this memory and compares it with a known value If the checksum matches the ROM test passes To run the test 1 Select the TEST ROM option and press Enter 2 Wait for the sampler to complete the test 3 When finished th
122. ower supply with the AC and compressor see Figure 1 10 Ensure that these cables are side by side and not crossed during reassembly A Permagum sealant Power supply cables Adhesive strips Figure 1 10 Rear view with module removed Adhesive strips Permagum sealant power cables 1 Permagum is a registered trademark of the Presstite Engineer ing Company 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance ao Adhesive Center strip screw aun SS LI ts D OOI E Permagum i eines TE sealant i Ahihihi PHILA thai titih Figure 1 11 Rear view of refrigeration module Adhesive strip Permagum sealant Reinstall the refrigeration module tipping the top back while sliding the bottom forward insulation rear panel and cover brace reversing the steps in Section 1 7 When the bottom is in place push the top into place Push top in second Push bottom in first Figure 1 12 Slide refrigeration module into place A CAUTION When reinstalling all self tapping screws avoid destroying the plastic threads First seat each screw in its hole and without pressing down rotate the screw counter clockwise until it falls into its thread groove with a click Then tighten the screw Reinstall the refrigeration module mounting screws 8 insu lation panel back cover screws 5 and cover brace screws 2 Hold the line cord taut to remove any slack and attach
123. r circuitry on the CPU The current coming in flows through zener diode CR28 and the 10 ohm resistor R98 The zener drops 4 7 volts to provide a local power source for the isolated circuitry The rest of the voltage drops across R98 which is the sensing element U35 is a voltage to frequency converter that runs on the isolated 4 7 volts and outputs an AC signal based on the voltage across R98 The pulses from U35 go through opto isolator U34 which delivers them to Schmidt trigger U25 B and the U7 The pulses are then counted by the CPU U15 is a 2 5 volt reference It provides Vref to the CPU for the a to d converter It also provides power to the two refrigerator temperature sensors 4 5 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 4 2 Test Points Test Point Test points and their values for the 5800 CPU are listed below in Table 4 1 See the schematic diagram in Figure A 4 Appendix A which shows their board connections in red for easier viewing Table 4 1 Test Point Functions and Values Function 2 5V reference voltage Value 2 462 to 2 538 volts 1 5 accuracy Home output from distributor stepper motor driver Goes low when both phases are being driven at 70 7 Liquid Detect after filter This is the filtered AC signal from the liquid detector MCKO Master Clock Output This out put is enabled when in the CPU board test mode TEST command through the serial port See
124. refrigeration module mounting screws Note that the refrigeration module has an adhesive strip just above the rear coils The bottom center screw may be slightly hidden by this strip 5 Carefully pull the module out and rotate clockwise to expose the wiring connectors Figure 1 9 A CAUTION During removal keep the module as close to the refrigerator body as possible to avoid pulling the wiring taut and damaging the connectors Turn module out and left Se be Sis iA x ma z Ss S Ste lt gt Adhesive Since strip is Ke Se a Figure 1 9 Remove the refrigeration module mounting screws 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance 1 8 Closing the Rear Ensure that the control wiring runs through the notches in the Compartment plastic refrigerator body The refrigeration module and rear compartment of the cabinet have adhesive strips and Permagum caulking cord sealant pro tecting the components Figures 1 11 and 1 10 Ensure that all adhesive strips and Permagum are still in place before reassembly A CAUTION The adhesive strips and Permagum are required to prevent air flow between the condenser coil and the evaporator plate Without this protection water condensation on the coil will cause ice build up resulting in poor refrigerator performance and inability to shut off M Note Two thick black cables connect the p
125. rge 3 The sampler displays the On Off ratio To pass the number must be between 0 8 and 1 25 5 3 5800 Refrigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics 5 1 6 Test Distributor If the sampler displays PUMP FAILURE or BAD ON OFF RATIO turn off the sampler by pressing the Off button Then refer to Section 1 4 1 and perform a pump inspection Clear any obstruc tions from the pump housing and pump tube verify that the pump rotor turns then perform the TEST PUMP diagnostic again If you don t find obstructions to pump rotor movement but the pump still fails contact your authorized Isco service facility or the Teledyne Isco factory The TEST DISTRIBUTOR diagnostic calibrates the sampler s dis tributor alignment You specify the bottle position to which the sampler should move the arm You can then verify the correct positioning of the arm M Note This test is not applicable for samplers configured for operation with a single 20 liter bottle To run the test 1 Remove the discharge tube from the distributor arm This removes tension from the arm for better visual verifi cation Figure 5 1 Distributor arm A discharge tube B and stop C 5 4 SELECT DIAG lt gt TEST DISTRIBUTOR 2 Goto the RUN DIAGNOSTICS menu as usual and select the TEST DISTRIBUTOR option 3 Open the refrigerated compartment and manually move the distributor arm to its ho
126. roduces 5 volts This voltage is used by the display backlight and the general outputs Vp goes through a linear regulator VR1 to become 5 volts for the circuitry of the LCD display and its associated circuitry U9 converts the analog 3 3 volts into 3 3 volts for use by the analog circuitry of the liquid detector The serial data is handled by the UARTs built into the CPU The Tx and Rx lines go through U1 which converts between logic level and RS232 voltage levels This chip generates its own neg 4 1 6 Flow Meter Interface U25 36 P12 4 1 7 Liquid Detector U4 10 P2 4 1 8 Temperature Inputs U12 P3 4 1 9 Microprocessor Supervision U18 4 1 10 Distributor Motor Drive U40 P11 Rotation Sensor P14 U32 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply ative voltage to supply the negative levels needed for RS232 Channel 0 goes through the flow meter connector P12 The receive line shares the inhibit input from the flow meter Channel 1 is not used at this time but is brought to TP1 and TP2 The flow meter connections come in through P12 All of the 4 signal lines are protected by transzorbs and filter capacitors Flow pulses and Inhibit from the flow meter go through Schmidt triggers in U25 Serial input RS232 shares the Inhibit line The Event Mark signal comes from the port on the CPU to U36 which is a solid state relay that outputs as a 12V signal The voltage gen
127. rrosion 3 Compare the temperature readings of the inlet and outlet coils the difference should be around 10 F 4 A visible coating of frost should form just above the orifice see Figure 3 11 3 12 Tubing 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System 5 Inspect as described in Table 3 2 and the paragraphs that follow 6 When you are finished checking the line pressure remove AC power from the sampler 7 Crimp the tubing shut behind the saddle tap Remove the saddle tap cut off the tubing end and braze with silver sol der to seal it 8 Coat all brazed areas and exposed metal with lacquer paint and cover with heat shrink tubing A CAUTION Do not leave a saddle tap installed after use It will cause leak age within a short time Inspect all tubing for dents bends and cracks in the paint The tubing can be damaged if struck by a hard object such as a tool or a fan blade Tubing must be refrigeration grade copper tubing and must be protected at all times from exposure to gases and other corrosive elements Gases can eat through the copper making it porous and prone to leaks and or oxidized material clogging the line All brazed areas and exposed metal must be coated with lacquer paint and then covered with shrink tubing 3 13 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System Refrigerant dryer If a leak is repaired replacement of the dryer is recom
128. s the sampler s keypad While the test is active the display reports the button name of any button you press There is no pass or fail message The tech nician must watch the display to determine if the sampler reports the correct button when it is pressed To run the test 1 Select the TEST KEYPAD option and press Enter 2 The sampler displays the test instructions 3 Press any buttons on the keypad in any order the display should report the button name as it is pressed For exam ple press the Enter button The display reports ENTER After 20 keystrokes the sampler reverts to the SELECT DIAG menu M Note Pressing the red Stop button twice consecutively will exit the test regardless of the number of strokes If the display does not report the button name when you press it the keypad could be faulty Contact your authorized Isco service facility or the Teledyne Isco factory The TEST PUMP diagnostic tests the sampler s pump assembly The sampler operates the pump in each direction and reports an ON OFF ratio This ratio is an indication of the pump s mechanical and electronic performance To run the test 1 Select the TEST PUMP option and press Enter The sam pler starts the test and continues without intervention To cancel the test you can press the Stop button 2 The sampler displays the On Off ratio To pass the number must be between 0 8 and 1 25 The test continues by oper ating the pump in reverse pu
129. shaft When seating the idler gear first lubricate its shaft with grease The black plastic bushing also known as the thrust bushing normally rests on the shaft of the drive gear acting as a spacer Figure 2 13 If replacing one or both of the bushings ensure that the bushing flanges rest on the motor gear side bottom of the plate Figure 2 13 Idler gear Drive gear with thrust bushing Figure 2 13 Idler and drive gears 2 10 5800 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2 3 6 Motor Replacement When installing the motor and plate assembly attach the plate to the base using the original four holes to insert the mounting screws see Figures 2 12 and 2 14 The unused holes should only be used if the original threaded holes are damaged Tighten the screws to 20 28 in lbs A CAUTION When reinstalling all self tapping screws avoid destroying the plastic threads First seat each screw in its hole and without pressing down rotate the screw counter clockwise until it falls into its thread groove with a click Then tighten the screw This precaution is not necessary with new unthreaded holes Spare mounting lt holes 3 Original mounting holes Figure 2 14 Pump motor plate Wiring assembly The motor wiring harness is easily replaceable 1 Un solder the two wires from the motor terminals 2 When installing the new harness solder the red wire to the red terminal and the bl
130. silicone sealant Accessing the Temperature To begin removal replacement of the cable you must access the Cable interior and remove the refrigeration module by following the instructions provided in Section 1 7 Accessing the Rear Compo nents Then 1 Open the flip cover of the sampler and remove the control panel mounting screws Figure 3 1 Control panel module removal 2 Lift the control panel to expose the wiring connectors tak ing care not to put strain on the wires Removing the Cable 3 Disconnect the temperature sensor cable from the control Assembly board and set the control panel back in place AN CAUTION When disconnecting a cable connector always grasp the con nector itself and not the wires A CAUTION When connecting the temperature sensor cable to P3 on the control board ensure that it is not reversed The slots on the cable connector must be facing inward 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System 4 Remove the large ferrite bead from the connector end of the cable it snaps apart Retain the ferrite bead for instal lation on the replacement cable assembly Ferrite Bead Cable Connector Figure 3 2 Ferrite bead on temperature sensor cable connector end 5 The evaporator sensor is mounted on the sixth coil up on the evaporator Cut the ties holding the evaporator sensor in place and move it out of the frame DIO
131. so used as the Serial Data Output for use with PC connections Optional serial cable recommended available This pin is also used as the Serial Data Input for use with PC connections Optional serial cable recommended available Output from internal driver is current limited to 100 mA maximum The output between the alarm pin and ground can drive low power alarm devices rated for 5 VDC Control higher power gt 100 mA devices or devices with different voltage re quirements through a user supplied relay See section 3 3 9 to configure alarm conditions 1 4 General Maintenance 1 4 1 Pump The following sections describe general inspection and mainte nance tasks to be performed on the 5800 Inspect the pump before each use Inspections are especially important when pumping large sample volumes over long dis tances or when the sample liquid contains a high percentage of suspended or abrasive solids Pumps in need of service might experience performance problems such as e Faulty liquid detection e Inaccurate sample volumes e No liquid pumped e Pump jams To inspect the pump 1 Press the On Off button to place the sampler controller in the Standby state This ensures that the sampler will not attempt to operate the pump You can also disconnect the power to the sampler N WARNING The sampler has a safety interlock that prevents the pump from operating when the pump housing band is open DO NOT tamper with the pump housing and b
132. ssor and replace the cover A IN CAUTION D Earth ground bonding conductor Ensure that the green yellow wire is reconnected to this terminal 10 Route the AC power cord through the refrigeration module Secure it in place with the bushing Figure 3 18 11 230V 50 Hz Systems Only Attach the 230V plug adapter to the end of the power cord Slide the piece of plastic heat shrink tubing over the plugs Then apply a heat source of at least 80 C 176 F to shrink the tubing 12 Move the refrigeration module up to the rear of the refrig erator and replace the drain tube in the drip pan on the module Figure 3 22 Drain tube and drip pan 13 When reinstalling the refrigeration module use caution not to pinch the sensor wiring 14 Following the steps in Section 1 8 close the rear compart ment Restore AC power 15 After 30 minutes perform the refrigerator temperature diagnostic test Section 5 1 8 As the refrigerator cycles off and on the reported temperature will rise above and below the set temperature However the average reported tem perature should be the same as the configured tempera ture 3 22 3 5 Refrigeration Cool Down Test 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System Before beginning the cool down test look inside the refrigerator to ensure that the evaporator fan is running For the cool down test to pass the temperature inside the refrig erator must drop at a
133. system to rinse it If these items are severely contaminated replace them For application specific requirements consult with your labo ratory to establish cleaning or replacement protocols GTA B Oo A Strainer 316 stainless steel E Bulkhead Fitting 316 stain polypropylene or CPVC less steel B Suction Line vinyl F Discharge Tube silicone Tubing Coupler G Bottle glass polypropylene or polyethylene D Pump Tube silicone 5800 Refrigerated Sampler Service Guide Section 1 Introduction and General Maintenance 1 4 6 Refrigerator Cleaning Keeping the sampler clean and protected from harsh elements Guidelines may extend the usable life of the sampler When necessary clean the exterior and interior of the sampler with warm soapy water and brush then rinse with water Be sure to use a detergent that is compatible with low density polyethylene and polystyrene Avoid using strong solvents and acids 1 5 Software Some issues with the 5800 may be resolved by installing the latest software version or resetting the instrument This section provides information related to the sampler s software 1 5 1 Updating the Software The software update is stored as a zip file A CAUTION Updating the sampler s software affects the program settings and may completely erase the stored data Record program settings and collect all data from the sampler before proceed
134. t U7 25 34 35 P13 2 ee ene 4 5 AAG Vref U15 in Sie RES ad 4 5 Test Points a nk wd ee an 4 6 CPU Board Tests ici SE EE BIE BPI EN a IR ee ba RA 8 4 7 4 3 1 TIME DATE Read Write 0 0 ccc eee o 4 7 4 3 2 Sampling Reports 0 ccc cece nent eens 4 7 4 3 3 Functional T sts oinnes on a a ees 4 7 Control Panel hate Lt Rda ados wh es dal es Lo 4 11 4 4 1 Software Version o eee eee teen E 4 11 4 4 2 Control Panel Removal 0 ccc eee ees 4 12 4 4 3 Control Panel Installation 0 0 0c ee eee eee 4 12 4 4 4 Power Backup 0 cece ccc eee a a a a 4 14 Power Supply a whee 4 15 4 5 1 Power Supply Removal 0 0 00 c cece teen ee as 4 15 AL BD A kh seo CST we A Sw EE I GEE EEE Bu 4 20 5800 Refrigerated Sampler Service Guide Table of Contents 4 5 3 Power Supply Replacement 0 cece eee 4 20 4 6 Line Cord rs RRS SS Regn A A Raab e 4 22 4 6 1 Line Cord Removal 0 0 cece eee eens 4 22 4 6 2 Line Cord Replacement 0 00 c cece eree 4 25 Section 5 Electrical Troubleshooting and Diagnostics 9 1 5800 Diagnostics ica seas eed Sea oe ay Sa ee la 5 1 5 1 1 Test RAM nin eerie ahd ite nda be Based cease Sane Se Pane 5 2 DE Test ROM eii E st sare ah Mace eae ee 5 2 SLs Test Display ita ta Sot ee eS Aye eS PESTS 5 2 pl Test Keypad iia ns otic atk ab tata hush Win hia eh eh ia 5 3 5 1 5 Test PU DFs pad a ei eed SOA ee hae eee eee es
135. t the rubber housing should not be visibly dented 10 Gently press the metal sensor into the plastic holder behind the power supply plate until it snaps into place 11 Replace the refrigeration module insulation rear panel and cover brace as detailed in Section 1 8 Closing the Rear Compartment The electronics compartment is protected from moisture conden sation by an internal heater on the main CPU board If the 5800 has been connected to AC power for at least half an hour the temperature within the electronics compartment should be greater than the ambient temperature This temperature is measured by a sensor mounted on the board See Section 5 1 9 for instructions on how to view the com partment temperature readings Should there be a need to verify the temperature readings dis played by the control panel it is important to read the temper ature as close as possible to the sensor inside the refrigerator To verify the temperature without a 24 bottle rack or locating base place a thermometer in a container of water in the right rear corner of the refrigerator The thermometer should sit in front of the return air opening to the refrigeration system but not obstruct the air flow 3 7 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System To verify the temperature with the 24 bottle rack place the refrigerator thermometer on the rack near bottles 20 and 21 Figure 3 6 For samplers with the bottle
136. tal All bare metal must be covered Apply 15 of cork insulating tape to the suction line begin ning at the compressor and ending even with the bottom of the metal tab on the frame Suction line wrapped in cork tape High pressure service port covered with heat shrink Figure 3 12 Protective coverings for suction line and service ports 3 16 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System 3 4 4 Condenser Fan The condenser fan rarely needs replacement A bent fan blade debris blockage or loose connection can often be corrected by hand In the rare case of fan motor failure replace the fan Service check If the fan does not run when powered it will need to be replaced To verify motor failure disconnect the fan from the compressor and measure the resistance across its two connectors Normal resistance is between 50 and 150 ohms If the motor has burned out the resistance will be very high open Tools Multimeter 16 nut driver 2 Phillips screwdriver Removal replacement 1 Pull the plastic terminal cover away from the compressor The cover is sometimes difficult to loosen be careful not to break it 115V 230V Figure 3 13 Terminal cover 2 The fan harness has two thick black wires one smooth and one ribbed ending in one female flag terminal and one female spade terminal 115V or two female spade termi nals 230V Disconnect the wires from the relay Figure 3 14 3
137. ter 2 The voltage is displayed The voltage reading is normally between 2 8 and 3 1 VDC If the voltage is below 2 8 VDC the internal battery should be replaced Contact your authorized Isco service facility or the Teledyne Isco factory for assistance 5 7 5800 Refrigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics 5 1 12 Loaded Battery Voltage SELECT DIAG lt gt LOADED BATTERY VOLTS LOADED BATTERY VOLTS ac Vi 5 1 13 Display Analog Input 5 8 M Note Should there be a loss of AC power and the internal battery s no load voltage is below 2 8 VDC the sampler might lose data and settings from its memory It is recommended that you retrieve the data and record the program and configuration set tings in case of memory loss The LOADED BATTERY VOLTS diagnostic displays the loaded DC voltage supplied by the Main CPU board s internal battery A loaded test provides a better indication of battery performance When this test is started the sampler will display the voltage with a 20KQ load at one second intervals The test continues for 15 seconds or until you press the Enter button to abort the test M Note Repeated use of the Loaded Battery Volts diagnostic will shorten the battery life To display the loaded battery voltage 1 Select the LOADED BATTERY VOLTS option and press Enter 2 The display shows the voltage at 1 second intervals for 15 seconds You c
138. trical Troubleshooting and Diagnostics 5 10 5800 Refrigerated Sampler Service Guide Appendix A Electrical Diagrams Electrical wiring diagrams for 115V and 230V models can be found in Figures A 2 and A 3 respectively See Figure A 4 for a schematic diagram of the 5800 CPU CBA The schematic shown is for the current version with battery backup capability Note that this manual does not contain all versions of electrical diagrams To access electronic copies of schematics visit http www isco com support schematics asp and enter the serial number for the correct schematic version for your sampler The serial tag is located on the interior wall beneath the fan Figure A 1 Serial Tag Figure A 1 Location of serial tag A 1 5800 Refrigerated Sampler Service Guide Appendix A Electrical Diagrams A 2 5800 Refrigerated Sampler Electrical Wiring CB2 PUMP INTERFACE ES 5 x XR de y Xx BN IN COMPONENT SIDE Y e TT A No AX pe 1010 A 7 PUMP SENSOR V 2 Lo a I tA y 7 ho m PS2 WIT 9 al w N p PE ao wag veL ios de 3 pea Be o o O FEKI eT 3 COLOR CODES 58 2 y CPU re
139. tubing MUST be coated with acrylic paint and then covered with shrink tubing to prevent corrosion 5800 Refrigerated Sampler Service Guide Section 3 Refrigeration System 3 4 3 Refrigerant Charging On site charging must be performed by licensed service per sonnel only Consult local laws regarding refrigeration repair Ay WARNING Do not run the compressor during evacuation leak testing or charging 1 2 Through the low pressure service port evacuate the sys tem to 150 microns or less Through the high pressure service port pressurize the sys tem with dry nitrogen before charging to ensure that there are no leaks If there is a leak in the refrigeration system replacement is recommended See the procedure in Section 3 4 5 for details about system replacement Through the high pressure service port charge with 5 50 0 10 oz of refrigerant HFC R134a A CAUTION The correct amount of refrigerant is critical to proper operation of the 5800 6 When charging is complete crimp the high pressure ser vice port near the joint and the extension close to the tee Braze the ends of the service port tubes with silver solder to seal Coat any exposed copper tubing with acrylic paint A CAUTION All exposed copper tubing MUST be coated with acrylic paint and then covered with shrink tubing to prevent corrosion 7 8 Slide the 3 shrink tubing over the joints and shrink seal to protect the me
140. vice Guide Section 4 CPU and Power Supply 4 26 5800 Refrigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics 5 1 5800 Diagnostics The sampler has built in diagnostics routines that trained service technicians use to confirm that all sampler subsystems are working correctly or to locate faults Many of the diagnostic routines also can be run in the field In many cases the sampler will determine if the test passes or fails e Ifatest passes the sampler displays a message showing the test passed and emits a short beep e Ifa test fails the sampler displays a message with some detail about the failure The unit will emit a wavering tone for five seconds In a few cases the service technician must determine if the test passed or failed based on a sampler function that must be observed The sampler automatically reverts to the SELECT DIAG menu after displaying the test results or when the test is complete or expired To start the diagnostics from the standby screen BROGRAMI CONFIGURE 1 Select the CONFIGURE option and press Enter VIEW LOG SELECT OPTION lt gt 2 Press the Previous button until the RUN DIAGNOSTICS RUN DIAGNOSTICS option is displayed Press Enter 3 The sampler displays a diagnostic option Press Enter to start the test or press the Next or Previous buttons to scroll through the diagnostic options Refer to the following sections for specific information ab
141. which sinks the motor current from P7 2 The current from Q9 then flows through the interlock FET Q8 to ground The reverse circuit is similar with the Pump Reverse signal going through gate U21 opto U23 and on to drive Q16 and Q12 which are the other two legs of the H bridge When the pump is called into operation the Pump Encoder Drive signal goes out through U31 to P9 thus turning on the LED in the pump opto Pump pulses come back in as the pump turns go through Schmidt trigger U32 d and into the CPU The compartment containing the CPU is heated to keep water from condensing on the board and eliminate the need for des iccant in this area The heater is R133 which is a 20 ohm 10 watt resistor It is driven by U33 a solid state relay It is on 20 of the time and delivers about 1 5 W of heat 4 1 14 General Outputs U37 U39 P13 4 1 15 Analog Input U7 25 34 35 P13 4 1 16 Vref U15 5800 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply There are four programmable outputs that come out on P13 These outputs provide logic signals at 0 or 5 volts U37 and U39 provide one of these two levels depending on the signal input to them The signals go through current limiting PTCs R118 119 121 and 122 and protection circuits P13 also has the analog input 4 20 mA which can come from a flow meter and provide flow data for flow proportional sampling This input is electrically isolated from the othe

5800 Refrigerated Sampler Service Manual

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