service manual
Contents
1. MANUAL 4 MODELS 7553 70 Variable Speed Drive Controller System 600 rpm 115v 7553 71 Variable Speed Controller only 600 rpm 115v 7553 80 Variable Speed Drive Controller System 100 rpm 115v 7553 75 Variable Speed Drive Controller System 600 rpm 230v 7553 76 Variable Speed Controller only 100 rpm 230v 7553 77 Variable Speed Drive Controller System 600 rpm 230v CE 7553 85 Variable Speed Drive Controller System 100 rpm 230v 7553 87 Variable Speed Drive Controller System 100 rpm 230v CE 50002 02 Stir pak Heavy duty Mixer Controller 115 volt 50002 07 Stir pak Heavy duty Mixer Controller 230 volt 4554 10 Stir pak Dual shaft Mixer System 115 volt 4554 12 Stir pak Controller only 115 volt 7144 05 Micropump Variable Speed Drive 115 volt 7144 07 Micropump Variable Speed Drive 230 volt 7144 08 Micropump Controller only 115 volt 7144 09 Micropump Controller only 230 volt 7593 00 Variable Speed Drive Controller System 200 rpm 115v 7593 05 Variable Speed Drive Controller System 200 rpm 230v Information contained in this manual is proprietary to the BARNANT COMPANY division of COLE PARMER INSTRUMENT COMPANY INC No reproduction for other than the intended use of maintaining the product described herein is permitted without the permission of BARNANT Barnant Company Division of Cole Parmer Instrument Company Inc 625 East Bunker Court Vernon Hills Illinois 60061 1844 847 549 7600 847 247 2929 Fax 8002. 22 7 VDC at TP 6 by CR 7 LED DS 1 indicates power ON to circuitry Varistor VR1 and RC network amp suppress line noise generated externally and internally by motor and power bridge Output Drive A Motor power bridge consists of CR 3 CR 4 Q 1 Q 2 Diode CR 5 bypasses the inductive current surges of the motor when the power bridge shuts off The output bridge is routed through FWD OFF REV switch contacts to allow motor reversal and is brought out at J 7 and J 4 of the PCB Resistor capacitor combination consisting of R 5 and C 2 forms a snubber network for commutator noise suppression Control Section A B Motor speed is set by front panel pot 29 A VREF is obtained by regulating 22VDC supply with 13 and CR 11 to approximately 12VDC This is routed through network R 28 and R 29 to DC ground Adjustment pot R 28 sets maximum motor speed approx 10VDC at 1 Components R 14 CR 9 C 6 control acceleration deceleration of motor RPM Set speed is controlled and regulated by differential amp U1 and related components R 15 C 7 R 17 R 2 R 3 As motor load increases back EMF picked off drive output resistor network R 2 and R 3 TP 3 drops off This 15 fed through R 17 to pin 2 of U1 A causing TP 2 to charge integrator capacitor C 10 via R 18 to advance the SCR firing angle Current limit of circuit is accomplished by monitoring
3. 323 4340 A 1299 0437 Edition 06 TABLE OF CONTENTS PAGE SAFETY CONSIDERA TIONS caient item its detecti sateen 4 THEORY OF OPERA TION iii deia 5 DETAILED CIRCUIT OPERATION OF E 2720 amp E 2721 6 7 DETAILED CIRCUIT OPERATION OF E 2219 XX PCB ASSEMBLIES 8 9 TROUBLESHO O TIN SER UE 10 REPAIR PROCEDURES ai 11 13 REPLACEMENT PARTS ElS 14 16 CALIBRA TION PROCEDURE cats ao 17 18 FUNCIONAL TES 19 FUNCTIONAL SPECIFICATIONS ec 20 21 Service for this product is performed at three levels the customer distributor COLE PARMER and factory depot repair This manual describes distributor COLE PARMER service procedures Customer service procedures are described in the operators manual Customers are encouraged to perform service as described in the operators manual as well as in special circumstances where special skills and safety are not considerations To use this manual begin with the troubleshooting section to isolate the fault to a replaceable part The functional description and check out procedure sections are also helpful in determining the faulty part Distributor COLE PARMER repair is limited to replacement of modules as detailed in the replacement parts list section The repair procedures section deta
4. 721 0001 D 2736 7553 76 As of 6 99 E 2219 0002 E 2193 7553 85 D 2656 0001 D 2655 14 7553 85 As of 8 94 D 2721 0001 D 2736 7553 85 As of 6 99 E 2219 0002 E 2193 7593 05 As of 8 94 D 2721 0001 D 2736 7593 05 As of 6 99 E 2219 0002 E 2193 50002 07 D 2656 0001 D 2655 50002 07 As of 8 94 D 2721 0001 D 2736 50002 07 As of 6 99 E 2219 0002 E 2193 7144 07 D 2491 0002 D 2463 7144 07 As of 8 94 D 2721 0002 D 2736 7144 07 As of 6 99 E 2219 0005 E 2193 7144 09 D 2491 0002 D 2463 7144 09 As of 8 94 D 2721 0002 D 2736 7144 09 As of 6 99 E 2219 0005 E 2193 7553 77 D 2721 0001 D 2736 7553 77 As of 6 99 E 2219 0002 E 2193 7553 87 D 2721 0001 D 2736 7553 87 As of 6 99 E 2219 0002 E 2193 CONTINUED 15 The following is a list of commonly used parts applicable to the above model LISTINGS FWD OFF REV switch assembly 7553 50002 4554 amp 7593 B 3281 Non CE models switch sealing boot 7553 50002 4554 7144 amp 7593 A 2984 16 After repairs are made the unit must be tested to assure proper performance to specifications In many cases factory QC check out procedures can be used by servicing personnel to accomplish this For calibration procedures please refer to the following CAL SPECIFICATION listings table appropriate to the model that is being serviced 7553 16 sses catwisis 7553 77 7553 87 7593 00 7593 05 Additional technical sp
5. Q 6 and level shifted by a Darlington pair Q 3 amp Q 8 on 115 volt units or Q 8 amp Q 7 on 220 volt units fire the power bridge SCR Q 1 amp Q 2 R 7 limits the gate current while CR 6 amp CR 12 blocks back conduction of the Darlington pair E 2219 PC BOARD ASSEMBLY Power Supply A AC line is brought in at J 3 and J 4 and routed through FWD OFF REV switch contacts to power bridge consisting of CR1 CR4 100 VDC at TP 8 is dropped by series resistor R 26 and regulated to approximately 22 7 VDC at TP 6 by CR 7 LED DS 1 indicates power ON to circuitry Varistor VR1 and RC network amp suppress line noise generated externally and internally by motor and power bridge Output Drive A Motor power bridge consists of CR 3 CR 4 Q 1 Q 2 Diode CR 5 bypasses the inductive current surges of the motor when the power bridge shuts off The output bridge is routed through FWD OFF REV switch contacts to allow motor reversal and is brought out at J 1 and J 2 of the PCB Resistor capacitor combination consisting of R 5 and C 2 forms a snubber network for commutator noise suppression Control Section A B Motor speed is set by front panel pot connected to J6 A VREF is obtained by regulating 22VDC supply with 13 and CR 11 to approximately 12VDC This is routed through network R 33 and R 30 to DC ground Adjustment pot R 33 sets maximum motor spe
6. bottom of the unit 13 The following is a list of stockable main control PCB assemblies and their reference schematic diagrams for all indicated models 115 volt MODELS MODEL PCB REFERENCE SCHEMATIC 7553 70 D 2461 0001 D 2655 7553 70 As of 8 94 D 2720 0001 D 2736 7553 70 As of 6 99 E 2219 0001 E 2193 7553 71 D 2461 0001 D 2655 7553 71 As of 8 94 D 2720 0001 D 2736 7553 71 As of 6 99 E 2219 0001 E 2193 7553 80 D 2461 0001 D 2655 7553 80 As of 8 94 D 2720 0001 D 2736 7553 80 As of 6 99 E 2219 0001 E 2193 7593 00 As of 8 94 D 2720 0001 D 2736 7593 00 As of 6 99 E 2219 0001 E 2193 50002 02 D 2461 0001 D 2655 50002 02 As of 8 94 D 2720 0001 D 2736 50002 02 As of 6 99 E 2219 0001 E 2193 7144 05 D 2465 0002 D 2463 7144 05 As of 8 94 D 2720 0003 D 2736 7144 05 As of 6 99 E 2219 0004 E 2193 7144 08 D 2465 0001 D 2463 7144 08 As of 8 94 D 2720 0003 D 2736 7144 08 As of 6 99 E 2219 0004 E 2193 4554 10 D 2641 0002 D 2669 4554 10 As of 8 94 D 2720 0002 D 2736 4554 10 As of 6 99 E 2219 0003 E 2193 4554 12 D 2641 0002 D 2669 4554 12 As of 8 94 D 2720 0002 D 2736 4554 12 As of 6 99 E 2219 0003 E 2193 230 volt MODELS MODEL PCB REFERENCE SCHEMATIC 7553 75 D 2656 0001 D 2655 7553 75 As of 8 94 D 2721 0001 D 2736 7553 75 As of 6 99 E 2219 0002 E 2193 7553 76 D 2656 0001 D 2655 7553 76 As of 8 94 D 2
7. des current feedback to the regulator circuits CR1 and CR2 with CR3 and CR4 form the secondary power bridge for the power to the regulator circuits R26 is a voltage dropping resistor from line voltage to the 22V used by the regulators CR7 limits the voltage to 22V CR6 decouples the pulsating DC used to synchronize the SCR firing circuit to the line from the steady DC filtered by C5 used to power the regulator circuits and stabilize the speed reference signal and R12 provide the voltage reference and line synchronization for the PUT Q5 used to fire the power bridge SCR s CR13 provides a 10 Volt window to allow SCR s to turn off at each line cycle R14 CR9 and C6 form the soft start circuit which provides a gentle acceleration of the motor R31 and R16 compensate for the voltage drop introduced by the motor armature resistance thereby improving load regulation of the drive CR10 and C09 form a current peak detector which is buffered by R24 and Q04 Q6 and Q3 form a pulse amplifier and level shifter to fire the power bridge SCR s The SCR used for Q3 in the 220 vac units Q7 is configured to act like a high voltage PNP transistor E 2720 amp E 2721 PC BOARD ASSEMBLIES Power Supply A AC line is brought in at J 3 and J 4 and routed through FWD OFF REV switch contacts to power bridge consisting of CR1 CR4 100 VDC at TP 8 is dropped by series resistor R 26 and regulated to approximately
8. ecifications are available in the unit s OPERATOR MANUAL Because this manual is covering approximately 14 different models exact calibration procedures will differ between each unit However the following procedure may be used to roughly calibrate an out of spec unit 17 BEFORE PROCEEDING FURTHER PLEASE NOTE ALL WARNINGS AS LISTED IN THE SAFETY CONSIDERATIONS SECTION A 1 Phillips screwdriver B Non metallic pot tweaker C Hand held tachometer 1 Remove the four pan head screws at the bottom of the unit 2 Position top half of cover so that adjustment pots are accessible 3 Connect drive motor to controller 4 Plug unit into the appropriate line voltage If this can be done through an adjustable variac to e g 115 vac 115 volt units or 230 vac 230 volt units 5 Turn unit on set speed control for maximum 6 Measure amp turn pot R 28 E 2720 amp E 2721 series PC Boards R 33 E 2219 series multi turn to obtain proper motor terminal voltage as follows 100 0 vde 5 vde for 115 vac units 90 0 5 vde 4554 10 4554 12 200 0 vde 1 0 vde for 230 vac units 7 Pot R 31 E 2720 amp E 2721 series PC Boards R 36 E 2219 series is used to set the units no load to full load response and therefore should not be field adjusted 8 Seal pot adjustments and reassemble unit 18 A Mate drive motor to specified controller B Power up controller at specified line voltage C Verify that c
9. ed approx 10VDC at 1 Components R 13 CR 9 C 6 control acceleration deceleration of motor RPM Set speed is controlled and regulated by differential amp U1 and related components R 15 C 7 R 17 R 2 R 37 R 3 As motor load increases back EMF picked off drive output resistor network R 2 R 37 and R 3 TP 3 drops off This is fed through R 17 to pin 2 of U1 A causing TP 2 to charge integrator capacitor C 10 via R 18 to advance the SCR firing angle Current limit of circuit is accomplished by monitoring the voltage drop of current sense resistor R 4 feeding it through R 19 and R 11 to level amp U1 B and related components As current through R 4 approaches 2 0 amps for 120 volt units 1 0 amps for 240 volt units voltage to TP 4 rises to approximately 4 0VDC This is fed through resistor network R 22 and R 23 at a 2 to 1 ratio into the peak detector CR 10 amp C 9 The output of the peak detector is buffered R 21 amp Q 4 by an emitter follower Q 4 amp R 25 amplifier which discharges integrator C 10 retarding the SCR firing angle The resultant firing angle will be proportional to the difference between the torque reference charging current R 18 and the torque feedback discharging current R 25 The SCR will fire when the integrator C 10 voltage is equal to the PUT Q 9 reference voltage VR 3 R 11 amp R 12 Line synchronization is achieved by allowing the reference
10. hat when speed adjust knob is turned fully counter clockwise that indicator line is directly above screened line on front panel G Install the four pan head screws on bottom of unit TO REPLACE MAIN CONTROL PCB ASSEMBLY A Follow the steps outlined in DISASSEMBLE UNIT B Replace main PCB assembly C Note wiring of chassis as follows 115 volt Models 230 volt Models BLACK from ac line cord to J 3 BROWN of power shell to J 3 WHITE from ac line cord to J 4 BLUE of power shell to J 4 ORANGE from motor socket to 2 ORANGE of motor socket to J 2 WHITE from motor socket to J 1 WHITE of motor socket to J 1 D Check calibration as per applicable CAL specifications E Follow the steps outlined in ASSEMBLE UNIT REPAIR PROCEDURES 7553 7593 50002 7144 amp 4554 SERIES AS of 8 94 TO DISASSEMBLE UNIT PROCEED AS FOLLOWS A Remove four pan head screws on bottom of controller B Carefully unplug all connectors from PCB and separate enclosure assembly from chassis assembly TO REPLACE PCB ASSEMBLY A Depress locking taps on PCB stand offs and remove PCB B Position new PCB over stand offs and place slight pressure on corners of PCB until it snaps down on stand offs C Reconnect four wire leads from chassis as follows 115 volt Models 230 volt Models BLACK from ac line cord to J 3 BROWN of power shell to J 3 WHITE from ac line cord to J 4 BLUE of power shell to J 4 ORANGE from motor socket
11. ils disassembly and assembly procedures After repair the product should be calibrated and checked for proper performance Please refer to the operators manual pt A 1299 0484 A 1299 0472 A 1299 0555 or A 1299 0405 for A APPLICATIONS DATA B PRODUCT DESCRIPTION C INSTALLATION D SETUP E OPERATION F USER CALIBRATION G USER TROUBLESHOOTING amp MAINTENANCE H ACCESSORIES I SPECIFICATIONS Servicing must be performed only by personnel trained and skilled in the methods of troubleshooting and repair of electro mechanical products Use of procedures other than those described in this manual may result in a safety hazard to service personnel and or customers When servicing any component of this unit be absolutely certain that all power to circuitry is removed If any functional checks are to be performed while power is applied and chassis is disassembled care must be exercised for the following WARNING A THIS IS A LINE OPERATED DEVICE AND IS NOT ISOLATED FROM GROUND USE OF AN ISOLATION TRANSFORMER IS STRONGLY RECOMMENDED B DO NOT INADVERTENTLY SHORT ANY PART OF THE PRINTED CIRCUIT CARD TO GROUND AS SEVERE DAMAGE WILL RESULT C MAKE ABSOLUTELY SURE THAT ANY TEST EQUIPMENT USED FOR REPAIR IS NOT REFERENCED TO EARTH GROUND E 2720 amp E 2721 PC Board Assemblies Only The variable speed controller employs a phase controlled rectifier bridge to vary the power applied to a permanent magnet DC motor The b
12. ontroller drives motor properly D Refer to the CALIBRATION Section for additional information regarding the controller 19 MODEL NOM MIN MAXIMUM 7553 70 115 volts 90 volts 130 volts 7553 71 115 volts 90 volts 130 volts 7553 80 115 volts 90 volts 130 volts 7553 75 115 volts 90 volts 130 volts 7593 00 115 volts 90 volts 130 volts 50002 02 115 volts 90 volts 130 volts 4554 10 115 volts 90 volts 130 volts 4554 12 115 volts 90 volts 130 volts 7144 05 115 volts 90 volts 130 volts 7144 08 115 volts 90 volts 130 volts 7553 75 230 volts 190 volts 260 volts 7553 76 230 volts 190 volts 260 volts 7553 86 230 volts 190 volts 260 volts 7593 05 230 volts 190 volts 260 volts 50002 07 230 volts 190 volts 260 volts 7144 07 230 volts 190 volts 260 volts 7144 09 230 volts 190 volts 260 volts 7553 77 230volts 190 volts 260 volts 7553 87 230 volts 190 volts 260 volts 20 MINIMUM MAXIMUM OPERATING TEMPERATURE 00C 400C STORAGE TEMPERATURE 450C 650C HUMIDITY NON COND 10 90 All controller housings meet INTERNATIONAL ELECTRIC CODE 34 5 amp 529 IP CODE 53 RATING SIMILAR TO NEMA 5 AND 12 RATINGS 21
13. ridge will conduct current only when the power line voltage exceeds the voltage across the motor terminals The power to the motor can therefore be controlled by varying the point at which the bridge starts to conduct relative to the phase of the line voltage The phase angle at which the bridge starts conducting is controlled by an inner torque outer speed regulator loop The speed of the motor is directly proportional to the back EMF generated by the motor Comparing the voltage across the motor terminals against the speed reference signal at the center tap of the front panel speed control pot R 36 U 1 generates a torque reference signal The torque supplied by the motor is directly proportional to the current supplied to the motor Ul amplifies the voltage drop across a load resistor providing a signal proportional to the current supplied to the motor The peak value of the signal is subtracted from the torque reference signal by Q4 The resulting torque error signal charges C10 firing Q6 and the power bridge SCR s and C1 provide transient voltage protection from power line surges caused by other power conversion equipment and lightning strikes R5 and C2 provide transient protection from surges created by motor brush noise and FVVD REV switching Q1 and Q2 form the main power bridge for the motor 5 provides a current path to allow shut off of SCR s and Q2 R2 and provide voltage feedback and R4 provi
14. the voltage drop of current sense resistor R 4 feeding it through R 19 and R 20 to level amp U1 B and related components As current through R 4 approaches 2 0 amps for 120 volt units 1 0 amps for 240 volt units voltage to TP 4 rises to approximately 4 0VDC This is fed through resistor network R 22 and R 23 at a 2 to 1 ratio into the peak detector CR 10 amp C 9 The output of the peak detector is buffered R 24 amp Q 4 by an emitter follower Q 4 amp R 25 amplifier which discharges integrator C 10 retarding the SCR firing angle The resultant firing angle will be proportional to the difference between the torque reference charging current R 18 and the torque feedback discharging current R 25 The SCR will fire when the integrator C 10 voltage is equal to the PUT Q 5 reference voltage CR 7 R 11 amp R 12 Line synchronization is achieved by allowing the reference voltage to drop to zero with each line cross thereby discharging C 10 through Q 5 C 10 amp Q 5 form a relaxation oscillator whose period is proportional to the rate of charge of C 10 When the voltage across C 10 is equal to the reference voltage the PUT Q 5 is forward biased and will conduct discharging C 10 through the base emitter junction of buffer Q 6 R 9 by passes any leakage current while C 11 filters out noise pulses The pulse output of the relaxation oscillator C 10 amp Q 5 is buffered and amplified by
15. to J 2 ORANGE of motor socket to J 2 WHITE from motor socket to J 1 WHITE of motor socket to J 1 D Check calibration per applicable calibration specification TO REPLACE LED ASSEMBLY A Using a small flat blade screwdriver gently pry open plastic tabs on LED assembly that hold lens to control panel B Lift lens out of control panel taking care not to lose or damage gasket C Install new assembly by sliding gasket on lens and inserting lens into panel D Hold lens against panel firmly and insert LED assembly into lens and apply pressure towards lens until taps lock on lens TO REPLACE SPEED POTENTIOMETER A Remove knob and mounting hardware B Slide pot assembly out of the control panel taking care not to lose the gasket C Install new pot assembly in reverse sequence D Verify that when the knob is turned fully counter clockwise the indicator line is directly above screened line on control panel TO REPLACE FWD OFF REV SWITCH 12 A Remove switch sealing boot using care to prevent damage to it B Slide switch assembly out of control panel noting which side keyway slot on bushing is facing C Insert switch assembly into control panel with keyway slot in proper direction reinstall boot and tighten until switch will not rotate TO REASSEMBLE UNIT PROCEED AS FOLLOWS A Carefully plug all connectors into PCB observing proper orientation of plugs B Reinstall the four pan head screws on the
16. use rating MOTOR WILL NOT REVERSE 1 defective FWD OFF REV switch replace switch assy MOTOR WILL NOT RUN assumed functional motor 1 defective FWD OFF REV switch replace switch assy 2 defective controller PCB ASSY replace main controller PCB ASSY LOSS OF SPEED CONTROL OR IMPROPER SPEEDS 1 defective controller PCB ASSY replace main controller PCB ASSY 2 unit out of calibration recalibrate controller MOTOR IMMEDIATELY RUNS WHEN POWER IS APPLIED 1 power output triacs shorted replace main controller PCB ASSY For additional information regarding the unit please refer to the following A 1299 0484 operators manual A 1299 0472 operators manual A 1299 0405 operators manual A 1299 0550 operators manual 10 7144 SERIES PRIOR TO 8 94 TO DISASSEMBLE UNIT PROCEED AS FOLLOWS A Remove speed adjust knob from front panel B Remove mounting hardware from potentiometer C Remove control switch sealing boot from panel D Remove the four pan head screws on the bottom of the unit E Remove the four pan head screws holding the PCB assembly to the front panel F Remove PCB assembly by gently pulling straight out TO REASSEMBLE UNIT PROCEED AS FOLLOWS A Install PCB assembly by placing into top cover B Install the four pan head screws holding the PCB assembly C Install control switch sealing boot to panel D Install potentiometer mounting hardware E Install speed adjust knob F Verify t
17. voltage to drop to zero with each line cross thereby discharging C 10 through Q 9 C 10 amp Q 9 form a relaxation oscillator whose period is proportional to the rate of charge of C 10 When the voltage across C 10 is equal to the reference voltage the PUT Q 5 is forward biased and will conduct discharging C 10 through the base emitter junction of buffer Q 6 R 9 by passes any leakage current while C 11 filters out noise pulses The pulse output of the relaxation oscillator C 10 amp Q 9 is buffered and amplified by Q 6 and level shifted by a Darlington pair Q 3 amp Q 8 on 115 volt units or Q 8 amp Q 7 on 220 volt units fire the power bridge SCR Q 1 amp Q 2 R 7 amp R 29 limits the gate current while CR 6 amp CR 12 blocks back conduction of the Darlington pair Repairs on this unit are basically confined to either the unit s control PCB and or the drive motor assembly Where possible swap known good parts to localize and isolate the problem The following is a list of possible problems and remedies UNIT DOES NOT TURN ON NO POWER LIGHT 1 fuse blown replace fuse 2 power cord not connected properly check amp replace 3 FWD OFF REV switch failure replace main controller PCB 4 unit connected to dead outlet verify supply is HOT UNIT BLOWS FUSES 1 motor drive failure check using known good motor 2 defective controller pcb replace return to factory 3 wrong fuse installed check f
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