SERVICE MANUAL
Contents
1. EEEKEEE SERVICE MAN UAL MODELS 75211 10 Variable Speed Drive 5000 RPM 115 V 75211 15 Variable Speed Drive 5000 RPM 230 V CE Mark 75211 60 Variable Speed Drive w Pump 9000 RPM 115 V 75211 62 Variable Speed Drive 9000 RPM 115 V 75211 65 Variable Speed Drive w Pump 9000 RPM 230 V CE Mark 75211 67 Variable Speed Drive 9000 RPM 230 V CE Mark PROPRIETARY 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 800 323 4340 A 1299 0983 Edition 01 TABLE OF CONTENTS PAGE SAFETY CONSIDERA TIONS eege 4 THEORY OF OPERATION widccstindccetter ccedderdereddendesnddendecetcexdcnedeerteccddardcenederdeceddentcardeevbent 5 TROUBLESHOOTING se ED CS 8 REPAIR PROCEDURES cort testes des 9 REPLACEMENT PARTS LISTING siste ti all 11 CALIBRATION PROCEDURE 5 ccs ccacetieccocceceecaceedeeeste eceeceeeeuacesesanencatedeeecstvedeacaectatpeseeae 12 FUNCTIONAL SPECIFICATIONS EE 14 INTRODUCTION Service for this product is performed at three levels the customer distributor COLE PARMER and factory depot repair This manual describes distributor2. COLE PARMER service procedures Customer service procedures are described in the operators manual Customers are encouraged to perform service as described in the operator s 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 DistributorrCOLE PARMER repair is limited to replacement of modules as detailed in the replacement parts list section The repair procedures section detail s 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 0852 for A APPLICATIONS DATA B PRODUCT DESCRIPTION C INSTALLATION D SETUP E OPERATION F USER CALIBRATION G USER TROUBLESHOOTING amp MAINTENANCE H ACCESSORIES 1 SPECIFICATIONS SAFETY CONSIDERATIONS Servicing must be performed only by personnel trained and skilled in the methods of troubleshooting and repair of electromechanical products Use of procedures other than those described in this manual may result in a safety hazard to service personnel and or customers A WARNING High voltage is present inside the unit when servicing any component of this unit be absolutely certain that all power to circuitry is removed I
3. firing angle will be proportional to the difference between the torque reference charging current R18 and the torque feedback discharging current R25 F The SCR will fire when the integrator C10 voltage is equal to the PUT Q9 reference voltage VR3 R11 amp R12 Line synchronization is achieved by allowing the reference voltage to drop to zero 10 volt window with each line cross thereby discharging C10 through Q9 C10 amp Q9 form a relaxation oscillator whose period is proportional to the rate of charge of C10 When the voltage across C10 is equal to the reference voltage the PUT Q5 is forward biased and will conduct discharging C 10 through the base emitter junction of buffer Q6 R9 bypasses any leakage current while C11 filters out noise pulses G The pulse output of the relaxation oscillator C10 amp Q9 is buffered and amplified by Q6 and level shifted by a Darlington pair Q3 amp Q8 on 115 volt units or Q8 amp Q7 on 220 volt units fire the Power Bridge SCR Q1 amp Q2 R7 amp R29 limits the gate current while CR6 amp CR12 blocks back conduction of the Darlington pair H For a detailed view of these signals see figure 2 waveform and related descriptions mee Ges x Sr E SEL Dez e ale da A i d Ke Lo E CH o i Figure 1 Typical controller board employed in the 75211 series drives Tek BiH 25 OkKS e 789 Acqs 6 JA 120 Hz ia 66 Hz Chi RMS 116 6 V Ch2 M
4. pot connected to J6 B A VREF is obtained by regulating the 22VDC supply with R34 and VR2 to approximately 12VDC This is routed through network R33 and R30 to DC ground Adjustment pot R33 sets maximum motor speed approx 10VDC at TP 1 C Components R13 CRY and C6 control acceleration deceleration of motor RPM D Set speed is controlled and regulated by differential amp U1 and related components R15 C7 R17 and R2 R37 R3 All scaling is done at 5volts full scale for all op amp circuits As motor load increases back EMF picked off drive output resistor network R2 R37 and R3 TP 3 decreases from 5 volts This is fed through R17 to pin 2 of U1 A causing TP 2 to charge integrator capacitor C10 via R18 to advance the SCR firing angle until the op amp equalizes its input voltages E Current limit of circuit is accomplished by monitoring the voltage drop of current sense resistor R4 feeding it through R19 and R11 to level amp U1 B and related 5 components As current through R4 approaches 2 0 amps for 120 volt units 1 0 amps for 240 volt units voltage to TP 4 rises to approximately 5 0VDC This is fed through resistor network R22 and R23 at a 2 to 1 ratio into the peak detector CR10 amp C9 The output of the peak detector is buffered R21 amp Q4 by an emitter follower Q4 amp R25 amplifier which discharges integrator C10 retarding the SCR firing angle The resultant
5. ACEMENT PARTS LIST The following is a list of stockable main control PCB assemblies and their reference schematic diagrams for all indicated models 11 5volt MODELS 230volt MODELS MODEL The following is a list of commonly used parts applicable to the above model LISTINGS CALIBRATION After repairs are made the unit must be tested to assure proper performance to specifications In many cases servicing personnel to accomplish this can use factory QC checkout procedures For calibration procedures please refer to the following CAL SPECIFICATION listings table appropriate to the model that is being serviced MODEL 75211 10 75211 15 75211 80 75211 62 CAL 1858 75211 65 CAL 1858 75211 67 CAL 1858 Additional technical specifications are available in the unit s OPERATOR MANUAL Because this manual is covering approximately 6 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 BEFORE PROCEEDING FURTHER PLEASE NOTE ALL WARNINGS AS LISTED IN THE SAFETY CONSIDERATIONS SECTION TOOLS REQUIRED A 1 Phillips screwdriver B Non metallic pot tweaker C Hand held tachometer PROCEED AS FOLLOWS 1 Remove the four pan head screws on each side of the unit s cover and lift off 2 Pots are adjusted from the topside using an insulated pot tweaker 3 Plug unit into the appropriate
6. CEDURES DANGER When servicing any component of this unit be absolutely certain that all power to circuitry is removed TO DISASSEMBLE UNIT PROCEED AS FOLLOWS A Remove the four pan head screws on each side of the unit s cover B Lift off cover TO REPLACE PCB ASSEMBLY A Slide PC board up and disconnect wire leads B Position new PCB in circuit board guides 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 switch to J 3 WHITE from ac line cord to J 4 BLUE of switch to J 4 WHITE from motor J 2 WHITE of motor to J 2 BLACK from motor J 1 BLACK of motor to J 1 D Check calibration per applicable calibration specification TO REPLACE SPEED POTENTIOMETER A Remove knob and mounting hardware B Slide pot assembly out of the control panel 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 S in Speed on control panel TO REPLACE ON OFF SWITCH A Remove switch B Slide switch assemblies out of control panel noting which side the terminals are facing C Insert switch assembly into control panel with terminals in proper direction TO REASSEMBLE UNIT PROCEED AS FOLLOWS A Carefully plug all connectors into PCB observing proper orientation of plugs B Reinstall the eight pan head screws on the cover of the unit REPL
7. ean 32 1 YV Chd Mean 1 84m Chd RMS 5 80mvV R V 3 sep 1996 09 38 29 Waveform 1 Test point 6 Waveform 2 Output of scr bridge across motor Waveform 3 PUT charging ramp test point 5 Waveform 4 Motor current measured using TEK TPC 202 current probe TROUBLESHOOTING Repairs on this unit are basically confined to either the units 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 ON OFF switch failure replace main 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 pcb replace return to factory 3 wrong fuse installed check fuse rating MOTOR WILL NOT RUN assumed functional motor 1 defective ON OFF switch replace switch assy 2 defective PCB ASSY replace main PCB ASSY LOSS OF SPEED CONTROL OR IMPROPER SPEEDS 1 defective controller PCB ASSY replace main PCB ASSY 2 unit out of calibration recalibrate PCB ASSY MOTOR IMMEDIATELY RUNS WHEN POWER IS APPLIED 1 power output triacs shorted replace main PCB ASSY For additional information regarding the unit please refer to the following A 1299 0852 operators manual REPAIR PRO
8. f any functional checks are to be performed while power is applied and chassis is disassembled care must be exercised A CAUTION A This is a line operated device and is not isolated from ground Powering the device under test using 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 THEORY OF OPERATION GENERAL OVER VIEW A The 75211 series controller board employs modular SMT technology see figure 1 to provide a single board solution employing an SCR based power amplifier to drive permanent magnet motors Power Supply A AC line is brought in at J 3 and J 4 and routed through ON OFF switch contacts to power bridge consisting of CR1 CR2 CR7 CR11 B The rectified voltage at TP 8 is dropped by series resistor R26 or R35 and regulated to approximately 22 7 VDC at TP 6 by VR4 C LED connected to J5 indicates power ON to circuitry D Varistor RV1 and RC network R1 amp C1 suppress line noise generated externally and internally by motor and power bridge Output Drive A Motor power bridge consists of CR7 CR11 Q1 Q2 Diode CR13 bypasses the inductive current surges of the motor when the Power Bridge shuts off B Resistor capacitor combination consisting of R5 and C2 forms a snubber network for commutation noise suppression Control Section A Motor speed is set by front panel
9. 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 4 Turn unit on set speed control for maximum 5 Measure amp turn pot R 28 multi turn to obtain proper motor terminal voltage as follows 50 0 vdc 5 vdc for 75211 10 90 0 vde 5 vde for 75211 60 amp 75211 62 180 0 vdc 1 0 vdc for 75211 65 amp 75211 67 100 0 vdc 5 vdc for 75211 15 NOTE The motor should be rotating CW when viewed from the output shaft of the motor If not reverse wires at J1 and J2 on PC Board 6 Pot R 31 is used to set the units no load to full load response and therefore should not be field adjusted 7 Seal pot adjustments and reassemble unit SPECIFICATIONS LINE VOLTAGES MODEL NOM MIN MAXIMUM 75211 10 115 volts 90 volts 130 volts 75211 60 115 volts 90 volts 130 volts 75211 62 115 volts 90 volts 130 volts 75211 15 230 volts 190 volts 260 volts 75211 65 230 volts 190 volts 260 volts 75211 67 230 volts 190 volts 260 volts LINE FREQUENCY All models SINGLE PHASE 50 60 hertz TEMPERATURE amp HUMIDITY MINIMUM MAXIMUM OPERATING TEMPERATURE 0 C 40 C STORAGE TEMPERATURE 25 C 65 C HUMIDITY NON COND 10 90
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