Service Manual
Contents
1. MODULATING VALVE 4 5 750 093 COMPRESSOR 1 3 HP USA 120V 60HZ 4 5 750 109 COMPRESSOR 1 2 HP EUR 240V 50HZ 4 5 750 023 PC BOARD MODULATING VALVE COMPRESSOR 120V 4 5 500 078 PC BOARD MODULATING VALVE COMPRESSOR 240V 4 5 500 086 COMPLETE REFRIGERATION ASSY TESTED 120V 5 575 056 COMPLETE REFRIGERATION ASSY TESTED 240 5 575 057 DECKLID ASSEMBLY 5 510 054 TEMP ADJUST KNOB 330 039 1 FOR MODELS 8001 8010 ONLY 3 FOR MODELS 9101 9110 ONLY XX01 Digital Controller Models 2 FOR MODELS 9001 9010 ONLY 4 FOR MODELS 9501 9510 ONLY XX10 Programmable Controller Models 5 FOR MODELS 9601 9610 ONLY PC BOARD COMPONENTS Programmable Digital Controller pg 8 DESCRIPTION PART Q5 Q6 Q7 ALTERNISTOR Q4015L9 200 109 MAIN CONTROL BOARD 500 075 OR 500 079 REF DESCRIPTION PART C1 17 43 46 CAPACITOR TANT 10uF 10V 2 3 5 6 7 8 16 18 19 27 29 3 2 33 36 37 38 39 41 42 44 51 9 10 11 12 14 15 26 28 45 C34 C40 C35 R1 R78 R79 R4 R5 R6 R7 R8 R17 R28 R30 31 32 33 45 46 47 49 R18 R20 R21 R29 R34 R48 R35 R43 R36 R44 R37 R42 R38 R39 R41 R53 R40 R84 R85 Q8 CAPACITOR CERAMIC MONOLITHIC 0 1 50V CAPACITOR TANT 1uF 35V CAPACITOR CERAMIC MONOLITHIC 18pF 100V CAPACITOR LYTIC 330uF 16V CAPACITOR CERAMIC MONOLITHIC 0 33uF 50V CAPACITOR TANT 4 7uF 10V CAPACITOR CERAMIC MONOLITHIC 0 0470 RES 100K 5 1 4W RES 2K2. een a Schematic DTC Display Board Programmable Digital Controller pg 12 DSY O2L22u405 ABU tI Br 1 ar er ut vt er zI vi 5959605 29 3 Oenn Don 20 9 22 101 NIEL 10022 NIL FS 1 Anotu x L ur Schematic Main Control Board 12 Programmable Digital Controller pg 13 AlddNS HOHO 005 Odrou OWLNOD NIVH QA Shee 1 0 1 t 1 1 1 1 t 1 1 0 p oh 0 1 1 t 1 1 i 1 BATYA ONILYINDOH BAUBAG I gt t 1 ANNO 5 305077 NI O30QN79NTI 53 708 55 SSAHL HOLIALOUS HOLIMG Opads I HOLIME OfadB t Ahn 5 HAIM E2UQH 25 AYLEOHUAHA 10 Avie ONTLHYLE 72004 aW ia RO ENEJ AG SUVA ACFE NO LENOUIJ J et ae ct oe mnm BIHEYHI JOL
3. 1 1 4W RES 499 OHMS 1 1 4W RES 475 1 1 4W RES 80 6K 1 1 4W RES 10K 1 1 4W RES 10K 5 1 4W RES 100K 0 5 1 4W RES 51 1K 1 1 4W RES 2 7K 5 1 4W RES ZERO OHM RES 500 OHM 0 1 1 4W RES 10K 1 1 4W RES 1 3K 1 1 4W RES 4 7K 1 1 4W RES 200 OHM 1 1 4W RES 10 OHM 1 1 4W RES 4 7K 5 1 4W RES 1K 5 1 4W TRANSISTOR PNP 2N3906 Programmable Digital Controller pg 9 1 U1 U2 U3 U4 U5 U7 U8 U9 U10 U12 U13 U19 U21 U14 U15 U17 U18 U20 U22 Y1 SPEAKER PIEZOELECTRIC MINIATURE IC MCROPROCESSOR HD63A03XP IC EPROM GIVE VERSION CODE WRITTEN ON CHIP IC RAM STATIC 43256 IC TRANSCEIVER 74HC245N IC PEEL 18CV8 35 IC 5V VOLTAGE REGULATOR LM2940CT IC DRIVER ARRAY ULN2003L IC RS232 DRIVER MAX233CPA IC WATCHDOG MAX690 IC QUAD ANALOG SWITCH DG211 AMP DUAL AD706JN IC A D D A CONVERTER PCF8591PN IC VOLTAGE REFERENCE 2 5V LM336Z 2 5 IC EEPROM 24 02 IC D FLIP FLOP OCTAL 3 STATE 74HC574 IC A D CONVERTER 16 BIT C5501 IC VOLTAGE REGULATOR 5V 79L05A OR LM320LZ 5 CRYSTAL 4 915 MHZ 200 114 200 115 200 116 200 117 200 118 200 119 200 120 200 121 200 122 200 123 200 133 200 125 200 127 200 128 200 129 200 130 200 131 200 132 200 113 DISPLAY BOARD 500 076 REF C13 C31 D1 D2 D3 Q1 02 R13 R14 R15 R51 R52 R81 R54 R55 R57 R58 R80 R82 DESCRIPTION CAPACITOR CERAMIC MON
4. AAG LHA EDIR 4 Hun 4 HUB HIF HQ 5279 Schematic Power Supply and Wiring Diagram 13 Programmable Digital Controller pg 14 sagu VANNS SRK UuoST112n3 a439T ATIUNYILXI 1 9 1 6 dIHO 258 1304 22254 ALIYYd ON 0096 I SNOILYIINAKHHOD 60 TD T 10021 HIZL NITL Nizw 10928 ANOTU 158 Schematic 9232 14
5. display the temperature of the sensors 3 The lower left temperature is the Head Sensor The lower middle temperature is the Suction sensor Disregard the ohms and voltage to avoid confusion 4 The Head sensor should read between 20 and 100 varying with operation reading of 51 C or 150 and higher is a defective sensor 5 Suction sensor should read between 20 and 20 C varying with operation A reading of 51 C or 150 C and higher is a defective sensor Programmable XX10 To access the head and suction temperatures from the microprocessor 1 Press the Function and Contrast buttons The display reads CONTRAST ADJUST PRESS UP or DOWN 2 press and HOLD Set Enter button until display changes to read the temperature of sensors 3 The lower left temperature is the Head Senson The lower middle temperature is the Suction sensor Disregard the ohms and voltage to avoid confusion 4 The Head sensor should read between 20 C and 100 C varying with operation A reading of 51 C or 150 C and higher is a defective sensor 5 The Suction sensor should read between 20 C and 20 C varying with operation A reading of 51 C or 150 C and higher is a defective sensor Example head and suction pressures and temperatures Full cooling power operation when fluid is above 0 C Set the set point temperature down to 10 C or below Refrigerant Head PSI Head Temp Suction PSI Suct
6. from the bath and make sure that it will reach both calibration baths Run a serial communications program as described above The commands used below are in between quotation marks and must be in upper case letters 1 a UNITS WITH FULL NUMERIC KEYPAD Programmable models xx10 Remove refrigeration and heating power connections if desired Turn on unit and press FCN 8 on keypad A1 lt return gt to see echoed characters from the keyboard Type C lt return gt and a menu will appear on the computer screen b UNITS WITH SIMPLE KEYPAD Digital models 01 While turning on Hold ON Button Down until SERIAL LINK COMMUNICATION appears on the display and a menu appears on the computer screen Select A from the menu and another menu will appear 2 for internal probe 3 Place probe into the bath near zero Celsius 0 C and type L Let probe settle to temperature and then type in the exact temperature and lt return gt 4 Place probe into a bath at a high temperature 100 C to 200 C and type Let probe settle to temperature and then type in the exact temperature and lt return gt 5 Numbers displayed should now be correct Place probe back in the low temperature bath to double check the reading 6 When correct type X The unit will tell you to wait while it stores the new calibration points ON MODELS WITH EXTERNAL PROBE If the model has an external probe and is in
7. need of calibration repeat steps 2 through 6 and substitute D for C in Step 2 If you enter the calibration menu and you are not ready to calibrate the unit just type X The unit will print the wait message just as in Step 6 but only store the current values SECTION 5 SPARE PARTS LIST REF DESCRIPTION PART CAP1 CAPACITOR MOTOR RUN 370VAC 6uF 120V 205 056 CAP1 CAPACITOR MOTOR RUN 440VAC 3uF 208 240V 205 060 1 TRIP CIRCUIT BREAKER WITH TRIP 12 120V 215 039 CB1 TRIP CIRCUIT BREAKER WITH TRIP COIL 6 AMP 240V 215 040 DSP1 DISPLAY BOARD TESTED 500 076 H1 HEATER TUBULAR 5 DIA COIL 1KW 120V 215 119 H1 HEATER TUBULAR 5 DIA COIL 1KW 240V 215 120 J1 LINE CORD 120V 6 FT 16GA WITH PLUG FOR USA CANADA 225 010 J1 LINE CORD 120V 8 FT 14GA WITH PLUG FOR USA CANADA 225 159 J1 LINE CORD 240V WITH PLUG FOR EUROPE 225 112 J1 LINE CORD 240V WITH PLUG FOR AUSTRALIA 225 115 J1 LINE CORD 240V WITH PLUG FOR GREAT BRITAIN UK 225 116 Programmable Digital Controller pg 7 PR1 51 52 1 1 MTR1 MTR1 PCB2 PCB2 MTR2 MTR2 PCB4 PCB4 PROBE RTD 100 OHMS 0C 4 WIRE 200 136 MOTOR MOUNTING KIT ORDER WHEN REPLACING MOTOR 510 020 FOR MODELS 8001 9001 9101 2 3 2 3 COMPRESSOR FAN AXIAL 4 120 2 3 215 196 COMPRESSOR FAN AXIAL 4 240V 2 3 215 197 COMPRESSOR FAN AXIAL 10 120V 4 5 750 006 COMPRESSOR FAN AXIAL 10 240V 4 5 750 021
8. OLITHIC 0 1uF 50V LED SQUARE GREEN LED SQUARE RED TRANSISTOR NPN 2N3904 TRANSISTOR NPN DARLINGTON TIP 110 RES 150 OHMS 5 1 4W RES 10K 1 1 4W RES 9 09K 1 1 4W RES 1K 5 1 4W RES 2 21 OHMS 1 1 4W RES 4 7K 5 1 4W RES 47K 5 1 4W RES 10K 1 1 4W Programmable Digital Controller pg 10 POWER SUPPLY 500 077 OR 500 085 REF BR1 2 C1 47 48 C50 D1 D6 F1 Q3 R1 R11 R12 R59 R61 R63 R75 R60 R62 R64 R76 R65 R70 R66 R67 R68 R69 R71 R72 R73 R74 R66 R67 R68 R69 R71 R72 R73 R74 R83 DESCRIPTION BRIDGE RECTIFIER 1 5A CAPACITOR LYTIC 1000 MFD 50V CAPACITOR LYTIC 2200 MFD 16V CAPACITOR LYTIC 330 MFD 16V CAPACITOR LYTIC 0 1 MFD 400V 0 47uF FOR 240V DIODE 1N4005 FUSE 2AG 250V 1 4 25 AMPERE TRANSISTOR HEXFET IRFZ 12 ND RESISTOR 100K 1 4W 5 RESISTOR 51 OHM 1 4W 5 RESISTOR 270 OHM 1 4W 1 RESISTOR 10K 1 4W 5 RESISTOR 33 2K 1 4W 1 120V RESISTOR 100K 1 4W 5 240V RESISTOR 100 OHMS 1 4W 5 Programmable Digital Controller pg 11 SECTION 6 SCHEMATICS amp WIRING DIAGRAM COOLING ON HEAT ON POWEA ON 03 R57 lt m 5 23 N F 2 a H x O lt a AN Or NASPR DISPLAY MODULE Cod eeqanacta 13 EUR RETAS 1 ________ 20 l i
9. Programmable Digital Controller pg 1 SERVICE MANUAL FOR DIGITAL AND PROGRAMMABLE MODELS Information is reserved for trained qualified technical personnel It includes schematics amp wiring diagrams Any repair or service to a unit is to be performed by a certified technician ONLY Attempting repairs outlined in this guide may result in voiding your warranty A Unplug The Unit Before Servicing FLUID 65 00 C FLUID 65 00 C SET 65 00 SET 65 00 C Programmable Models Digital Models 7310 8010 9010 9110 9510 9610 9710 8001 9001 9101 9501 9601 9701 TABLE OF CONTENTS Section 1 Troubleshooting Procedure Section 2 Refrigeration Temperature amp Pressures Section 3 Replace the Main Control Board Section 4 Digital Programmable Field Temperature Calibrations Instructions Section 5 Spare Parts List Section 6 Schematics amp Wiring Diagram Programmable Digital Controller pg 2 SECTION 1 TROUBLESHOOTING PROCEDURE Note If the unit seems to function normally but fails to control or hold temperature steady first perform instructions as in Conditions and Steps before Troubleshooting the Unit Conditions and Steps before Troubleshooting the Unit 1 a On units that have a HI LO pump speed switch on the rear panel set the pump speed to high and connect the Inlet Ou
10. ed SECTION 3 REPLACING MAIN CONTROL BOARD When removing replacing the main control board always remove replace the bath temperature probe s included with the board Temperature probes are calibrated to each board at the factory Do not lose the nylon washer between the board mounting bracket and the main board where the nut fastens This prevents a possible short circuit to the power supply board SECTION 4 DIGITAL PROGRAMMABLE FIELD TEMPERATURE CALIBRATIONS INSTRUCTIONS We recommend sending the Main Control Board Internal Temperature Probe and External Temperature Probe if supplied back to the factory You will require the following items 1 Computer with RS232 interface RS232 serial cable 2 Acommunications program We recommend the use of Procomm 3 communications software at 9600 baud 1 Start Bit 8 Data Bits 1 Stop Bit and No Parity Bit 4 Two baths one at zero Celsius 0 C and one at a high temperature 100 C 200 C or at the user s most commonly used temperature You must calibrate both calibration points together HIGH and LOW calibration points cannot be entered separately 5 NIST traceable standard thermometer s Ranging from 0 C to a temperature between 100 C 200 C For units without RS 232 interface socket Refer to schematic RS232 on page 14 for installation Programmable Digital Controller pg 6 For units with RS 232 socket If you are calibrating the internal probe remove the probe
11. ion Temp Freon R12 175 100 C 20 gt 0 SUVA MP39 190 100 C 18 gt 0 SUVA R134A 193 100 18 gt 0 When controlling at a stabilized setpoint temperature above 0 Programmable Digital Controller pg 5 Refrigerant Head PSI Head Temp Suction PSI Suction Temp Freon R12 90 to 110 40 to 60 20 to 10 15 to 35 SUVA MP39 92 to 112 40 to 60 20 to 10 15 to 35 SUVA R134A 92 to 112 40 to 60 2010 10 15 to 35 When fluid temperature is below 0 Refrigerant Head PSI Head Temp Suction PSI Suction Temp Freon R12 95 to 115 40 to 60 lt 10 15 C to 10 G SUVA MP39 97 to 117 40 to 60 lt 10 15 to 10 G SUVA R134A 97 to 117 40 to 60 lt 10 15 C to 10 G Note It is normal to hear a quiet click once every five seconds while the compressor runs This is the modulating valve turning on amp off Quick Valve Seat Check With a refrigeration pressure gauge attached to the suction line an easy check can be done to check the modulation valve and compressor valve seats for a good seal 1 The two black wires to the modulating valve go to CONN145 Remove this connector from the moducating PC board 2 Run the refrigeration for about 30 seconds The suction should drop below 20 1 3 Shut off the unit The pressure should not change for at least a minute 4 Replace CONN14 when finish
12. ith floating plastic or Teflon balls 6 To return to the factory default setting You may easily reset all parameters to factory default settings With the unit STANDBY mode press the UP ARROW key then the DOWN ARROW key then the ON key then select default EEPROM PROBLEM CORRECTIVE ACTION 1 a Check that CONN5 AND CONNG ribbon connectors on properly Display does not light up b Check 1 and for line voltage from HOT to NEUTRAL unit shows no activity c Check all supply voltages 9V 5V 9V and 5V d See section Replacing main control board section 3 2 Breaker trips unit has an RS232 Port 3 Breaker trips and unit has no RS232 port 4 Continuously heats with heat light off or Breaker trips and TRIAC FAILURE PRESS ON SWITCH message appears 5 Intermittent heat with heat light on or Unit not heating and heat light is off 6 Unit not pumping 7 Temperature won t reach setpoint temperature 8 Unit s temperature rises above setpoint temperature and heat light is on off Programmable Digital Controller pg 3 a Connect RS 232 port to a computer The faulty section will be listed Ignore RTC message in the first lines of text when turning unit on b Check that display board is properly plugged in c Check if U17 on Main Control Board is missing d See Replacing main control board section 3 e As a last solution rem
13. motion generates heat Check unit s specification for ambient temperature and conditions Try uncovering the bath s removing insulation adding a tap water cooling coil or a refrigeration unit Programmable Digital Controller pg 4 9 If below 0 try lowering the setpoint few degrees lower than the desired temperature Unit s temperature won t If it still does not work see section Replacing main control board section 3 cool down to setpoint b Refrigeration needs servicing temperature c Check for ice build up around tank or refrigeration coils Use suitable low temperature fluid 10 a Check that the RTD probe is within 0 3 ohms of the following table Readout not within 0 25 C of actual temperature 20 C 107 79 40 C 115 54 60 C 123 24 TEMPERATURE 0 C PR1 SENSOR OHMS 100 00 b If okay then see Replacing main control board section 3 11 a See 6 Unit not Pumping Unstable temperature b Refer back to Conditions amp Steps Before Troubleshooting The Unit control SECTION 2 REFRIGERATION TEMPERATURES Ambient temperature should be near 25 C Unit is in normal operating mode with fluid and set temperature displayed Digital XX01 To access the head and suction temperatures from the microprocessor 1 Press and hold the Set Enter button until display reads CONTRAST ADJUST PRESS UP or DOWN 2 Press and hold the Set Enter button until display changes to
14. ove trip coil connections from CB1 If the unit still trips then check for overcurrent If not then check if Q4 is shorted a Check that display board is properly plugged in b Check if U17 on Main Control Board is missing c See section Replacing main control board section 3 d As a last solution remove trip coil connections from CB1 If the unit still trips then check for overcurrent If not then check if Q4 is shorted a Triac Q5 or ISO2 may be shorted Lift R61 to check If heat stays on Triac is shorted If heat shuts off pins 4 and 6 of ISO2 should be shorted b Check that Triac Q5 is properly heat sinked with heat sink thermal compound grease and screws tightened a Unplug the unit Check heater resistance for 14 4 ohms for 120V unit or 58 ohms for 240V b Check continuity of heater wires c Check replace Triac Q5 and then Triac driver ISO2 See Spare Parts section 5 Check that setpoint is higher than the actual bath temperature See Replacing main control board section 3 Unit should visibly pump the fluid inside the reservoir If not check that the pump shaft spins freely and impeller s are in place If bearings are worn out replace the entire pump motor See Spare Parts List section 5 a Check heater resistance as in No heat 45 b Check that there is line voltage at heater c Check for DC on heater If more than 30 DC volts replace Triac The unit s stirring amp pumping
15. tlet connections with a few feet long length of 1 4 diameter or greater hose b On units without the rear HI LO speed switch plug the Inlet Outlet pipes with Nylon 1 4 NPT plugs If there is a pump speed selection menu set the pump speed to setting number 1 highest setting 2 Use the same fluid and the same setpoint temperature as used in the application 3 Unit should visibly pump the fluid inside the reservoir If not check that the pump shaft spins freely and impeller s are in place If bearings are worn out replace the entire pump motor 4 Check that the fluid or fluid mixture is a Watery not thick like maple syrup Viscosity lt 25 centistokes b Not boiling on the surface or freezing to the bottom of the reservoir or cooling coils and not within 5 of the freezing or boiling point of the liquid 5 If the Inlet Outlet connections were used for an external application and the unit operates properly try the following a Check that externally applied heat does not exceed the rated cooling power of the refrigeration or external heat loss does not exceed the 1000 watts of the heater Fluids within 40 of their boiling point can cause so much heat loss as to require more than the 1000 watts of heat provided by the unit especially in containers with a large open surface area b Cover uncover and add remove insulation of both the internal reservoir and external application and tubing Insulate the top of the fluid w
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