Heraeus Megafuge11
Contents
1. e Brake resistor ellow 100 ohm ch 100W ellow Power rectifier blue red 902578 The reproduction in whole or part of this design is forbidden All rights are reserved to Jouan Italia S r l2. dd HU WH SES SS SE Fig 16 Remove the front panel see par 5 1 Disconnect the wire harness to the contactor O Disconnect all cable uP PWR board and the protective earth wire Remove the electronic rack unscrewing the 4 screws located on the bottom of the centrifuge Unscrew the Mains front end rack 2 screws on the rear panel and 2 screws located on the bottom of the centrifuge Slide out the Mains front end rack Gas spring replacement e o E n Remove the front panel see par 0 Remove the centrifuge bowl see par 0 Remove the Electronic rack see par 0 Remove the Mains front end rack see par 0 Remove the gas spring unscrewing the bolt located inside the centrifuge underneath the protective ring Replace the gas spring reversing the steps Heraeus Megafuge11 Service Manual 11290095 22 Micro Processor PWR board replacement Remove the front panel see par 0 Disconnect all cables and wire harnesses from the board Remove the board unscrew the 5 nuts Replace the board reversing the steps ne ai A Don t f
3. It is an AC Induction Motor called squirrel cage motor is 3 comprised of a simple cage like rotor and a stator JL containing three windings The changing field produced by U the AC line current in the stator induces a current in the rotor which interacts with the field and causes the rotor to rotate No brushes are necessary in this design The base speed of the AC motor is determined by the number of poles built into the stator windings and the frequency of the c B AC input voltage Variable speed control of an AC motor 1 can be accomplished by increasing or decreasing the input pat ME frequency A load on the motor causes the motor to slip in 5 um t proportion to the load 3 o Fig 5 3 1 3 Power control operating principle It consist in a single phase rectifier in case of 120V is used in the voltage doubler configuration which converts the AC single phase source in a DC supply Electrolytic capacitors are used to provide energy storage for the DC supply A three phase inverter consisting of six IGBT is used to drive the motor Three phase AC is then generated by using sine wave pulse with modulation The microprocessor controls the voltages and frequency of the AC output supplied to the motor Because AC motor under sine wave excitation are also capable of generating a dynamic brake is used When the speed command is reduced in an AC drive the motor will regenerate The real part of the three phase power flows fr
4. Thermo ELECTRON CORPORATION Heraeus Megafuge1 1 SORVALL T 1 Centrifuges SERVICE MANUAL 11290095 CAREFULLY READ THIS MANUAL AND THE OPERATING MANUAL BEFORE REPAIRING YOUR INSTRUMENT THIS DOCUMENT IS PROPERTY OF THERMO ELECTRON CORPORATION it may not be duplicated or distributed without the owner s authorisation The validity of the guarantee is subject to the observation of the instructions and precautions described in this document Heraeus Megafuge11 Service Manual 11290095 1 Revision Status REV DATE AMENDED PAGES NOTES A Oct 2006 Initial release B Feb 2007 Extension to Sorvall T1 Heraeus Megafuge11 Service Manual 11290095 2 CONTENTS Ll AN PRODUC TION SR e T ER 4 DUrpose ntt d d dada ce a toL do etg edat et a oodd 4 w A OT E 5 gt DESCRIPTION AND THEORY OB OPERA Ee ee ae ee 6 Pi e A E 6 yo A eege 6 HS CAM ATION Ol SCAU LION Sira no o oo 7 Component e MU E 8 Mams Oneni ae ET ECL 8 Functional pEInCIpleS ss A ARA A eine AA nd Re A O 9 Manasementol EE 10 3 1 1 FL odUSLO oe A A A Ta 10 3 1 2 De MOO E 10 3 1 3 Power control operate pacien siii iii ii 10 Elec HOMES LI c 11 3 1 4 Gene rai ee Cr re nr Ld MM LM MI I MI UEM MM ME 11 3 1 5 Ditterences between models 290 V 120 V ida ds 11 3 1 6 Micro Processor FEWR DOI ne st tte editt med a disi dieto deti baee bestie edu leo note deo di 11 3 1 7 Hinbalanee dete COLON uoces tope toda alas calcetas 12
5. 3 1 8 POS SO date EM es 13 3 1 9 Hip ts Outputs CONCA lea tro 14 d DIAGNOSTIES AND REPAIRS 1 25 9007859 did tad clado 16 A O RR 16 MOSSI O Sera o T DI T utm 16 Erorcodes and m6 SA o 16 53 JREPLACEMENTS PROCEDURES ee si 17 Front Pane EE eegen 17 Era replacement seca 1L E 17 Centrifuge bowl removal See Fi Lans nur Minnie E ER tad 18 balance Sensor replace ment seS Pie 12 sia aaa aa 18 Motor replacement see PM eo tun ven eau ette E AA EOS 18 Speed sensor and shock absorbers replacement see fig 13 ss 19 Li TatcHr assembly EE 20 Replacementot the Td ET E ue TE 20 Replacement On Hd Tateh Spare Darts idolos 21 5 1 1 leese 21 3152 Ee fe placement snl oda cM E ME C uM HIM dE Ne 21 5 1 3 Reedi ay RNC PR 21 5 1 4 SOCIO LGN TERT Tr 21 Electronic rack and Mains front end rack removal see Fig 16 22 CAS SDL rec mE DE on does Do 22 Micro Processor 4 PWR board Pe placement doo nue a tn nent 23 EPRONITOpIICERICII zos os d ei oth D tol oL Omron ao te 23 6 DIAGNOSTIC AND CALIBRATION PROGRAM ina ias 24 Access tobe Dias nosie MENU srt ts IS id NETT asnos 24 Imbalance EE Side pen enee Eege doo rn nooo tn vo doo eneen 25 E MOTOR EE ee en i 26 ere 26 Centers device EL EE 26 57 dd PAR ES elg pr r M Q n 24 EE init nent en 27 ETE CHOICE Tack Dare PAS o Ten ee de 28 MO LOR SD ARS DOLLS 250 ES 29 ta A Fi DAT pa AE e OS 30 Mains front end Spare EE 31 ISo
6. 60 Hz Operating current max V Mains 5 5 Aims 230 V 9 5 Ams 120 V Power max steady 400 W Power max acceleration 930 W Heat dissipation 1195 BTU h Heraeus Megafuge11 Service Manual 11290095 6 Other Characteristics Microprocessor controlled 4 quick selection programs RCF control Work temperature T ambient AT Set reading speed 500 14600 rpm 10 100 rpm incr Acceleration profiles 5 shapes selectable Deceleration profiles 5 shapes 1 free coasting selectable Settimer from 0 30 min up to 99 min oo Pulse key Momentan Spin Electronic accelerometer imbalance detector Three Phase Induction Motor Direct drive Installation precautions The centrifuge is designed to be safe under the following conditions Indoor use Altitude up to 2000m Temperature from 5 C to 40 C Maximum relative humidity 80 for temperature up to 31 C Mains supply voltage fluctuation up to 10 of the nominal voltage A Incorrect installation will affect safety and equipment performances The machine must be installed in a dust and non corrosive environment 1 The Bench top must be rigid sufficiently strong and levelled 2 300 mm of free space gap must be left on each side of the machine behind to ensure the proper ventilation 500mm DO uem Y AJUUmn uda on Fig 1 The centrifuge could move as a result of rotor imbalance rotor d
7. Mains inlet and fuse holder Heraeus Megafuge11 Service Manual 11290095 31 Rotors and Accessories CATn DESCRIPTION ay 11210435 T41 Swing Out Rotor 11210246 941 Swing Out Rotor 4x200ml 11175750 T20 Microtiter Plate Rotor for 2 x 3 Plates 1157xg 11175755 AC15 4 Angle Rotor 30 x 15ml 17 5x100mm 11175756 11175754 AC50 10A Angle Rotor 6 x 50ml 11175741 AC2 14 Sealed Angle Rotor 24 x 1 5 2ml 11x39mm 11175743 DC6 11 Drum Rotor 6 Micro tubes Racks 11210351 AC2 13 Sealed FiberLite Angle Rotor 48 x 1 5ml AC100 10A Angle Rotor 6 x 100ml 38x101mm Heraeus Megafuge11 Service Manual 11290095 32 9 APPENDIX 1 Wiring diagram 230 V version 50 60Hz 2x4AT fuses Line filter 3A Main switch Brown Brown 903208 1 e AE ss gt Brown e D Brown D 1 902574 4 E B S 903208 2 d Blue z o 5 gt Blue 71 i hi LOADS Yellow green 902574 1 902574 3 Chassis 902574 5 902574 2 XX TE Display board 902574 Main earth 9 rack em Basement Front panel L_ Blu EE 903205 biu 902573 902558 Rack Encoder ac Terminal i Block i Thermoswitch B H i Contactor T d
8. 7 Imbalance detector The imbalance sensor detects the mechanical vibration of the motor which are converted in electric signal managed by the microprocessor In case of anomalous vibration the run is aborted El Imbalance sensor connector J4 uP PWR board di pin 1 Power Supply 12V pin 2 GND pin 3 SIGNAL Fig 8 S Heraeus Megafuge11 Service Manual 11290095 12 3 1 8 Speed sensor It is a magnetic encoder system based on aluminium disk holding two magnets and a Hall effect sensor underneath see Fig 13 Magnetic sensor connector J7 uP PWR board pin 1 GND pin 2 SIGNAL pin 3 Power Supply 12V selected by Jumper ST2 pin 4 Not used Heraeus Megafuge11 Service Manual 11290095 13 3 1 9 Inputs Outputs connection 230V version JOJO einje1adula iaAo jauBELuoJ12a a 01 pil sasyums 0 BE 90 ADDE snq 40 ju ud QUE ITABI Ov ADEZ indui Jazzu indui Japoa2ua CH LU DI IT agord duwag SP Josuas 33UEJEJLU A amp RE B TER HE i ge oeie Ja a TE CN amp A S HO NI oW 15 1 T omes EOL CTE ER p 5 iesu HH UL ASMP AS zess Imre Eus Er d sl b zr i AT AEA Te us Rb SIE adas Jamod JAAP PIEOJ SY AG Jo AS DLt Aejdsip pay pleogAay 10 wA FC mdul 55A gy ndino sip Cd ld LP er Fig 9 14 Heraeus Megafuge11 Service Manual 11290095 120V version 10 o0Lu aInjeladwapaag JaUBewojsaja 0 Pl sa2ugMs 0 zi aa 90 Agog smquoy 400 UI oyag aBp
9. Mylar 8 Press the pulse button whe secon calibration cycle will start 2500rpm 50 sec At the end of the run the imbalance level detected will be displayed N The imbalance level must be between 300 and 700 9 Exit from Diagnostic and calibration Program Press the button Stop to exit from Heraeus Megafuge11 Service Manual 11290095 25 7 MOTOR VERIFICATIONS Motor checking oimple electrical tests suggested to verify the status of the motor use a multimeter to measure resistance across the motor windings Check 1 Electrical continuity between all the two phases combinations In case of open circuit the motor will not run 2 Resistance of two phases values must be 7Q 2096 3 he difference between two phases should not differ more than 0 20 If not the motor doesn t run smoothly jerks Centering device assembly Verify 1 the correct washers sequence 2 the free movements of the washers 3 the washers must be properly greased Washers sequence n 1 Flat washer n 2 Spring washers n 1 Flat washer n 2 Spring washers n 1 Flat washer n 2 Spring washers n 1 Flat washer Fig 18 Heraeus Megafuge11 Service Manual 11290095 26 8 SPARE PARTS LIST Centrifuge spare parts A E Ee 3 ue EN M EX a RE RS FO d l HN a
10. measures against residual risk eventually occurring when handling a product that conditions of use are unknown Anyway residual risk can be further reduced by means of Individual Protection Devices gloves lattice made not yet used masks safe glasses Heraeus Megafuge11 Service Manual 11290095 0 3 DESCRIPTION AND THEORY OF OPERATION Description The Megafuge11 is designed to separate substances made of different density elements by Relative Centrifugal Force RCF Different rotating equipment can be used in order to match the sample containers and the required performances The maximum speed and by consequence the resultant RCF is a function of the rotor in use swing out rotor can usually carry an higher load than fixed angle or aerodynamic rotors which can spin at higher speed For more information on operating principle refer to the User s Manual Specification Dimensions Height H 3 5 cm Width W 40 cm Depth D 48 cm Packaging HxWxD 48 x 54 x 61 cm Weight Net weight 40 kg Net weight including packaging 45 kg Centrifugation characteristics Max allowable capacity swing out 4 x 280 ml fixed angle 6 x94 ml Max allowable density 1200 kg m Max allowable weight 1 34 kg Max speed swing out 4100 rpm fixed angle 14600 rpm Max RCF at Tip swing out 3176xg fixed angle 23113xg Working temperature Ta AT Max noise lt 63 dBA Electrical characteristics Operating voltage 230 V 10 50 60 Hz 120 V 10
11. 7474 E gt 50320672 lt Blue o o Blue Blue Blue E E gt gt 90320871 N LOAD2 e Yellow green 902574 1 902574 3 Chassis 902574 5 902574 2 Display board 902574 6 CH Main earth FEN Basement l_ Front panel rack Blu red 903205 Blug 1 902573 902564 902558 Rack Encoder aci Terminal Block Thermoswitch Br H Contactor kedy 902561 BIL ow SW19 e n LC1K0610F7 Imbalance sensor blue Blue 903212 903208 3 green Green 903212 red Red 903212 902564 brown Ep Brown 902573 100n 47ohm 9 Rifa PMR 209 MC blue 902573 902577 CMC35 TRANSFORMER Orange 289432 1901 St Es ES St EE 21 110 LL x Jo DD4D fe Reed mm m wh J15 J1 i keyboard and pilot leds Display 10 5VAC Motor 15V 12VDC Red J3 not used Black Solenoid Imbalance Motor sensor CPU and Power control 120V Black white not used Lid switch solenoid brake J13 Switch and solenoid Compressor Line resistors BR 9 Lid switch Motor command command power Ext Power Encoder thermoswitch 12V n not used rectifier J8 gt e white a e No UU 902565 Flat Cable Flat Cable Drawn by A Frollo 120V 60 Hz P2 Verified by o Eyelet Display and Keyboard A Frollo o Faston Braided sleeve ce y Wednesday October 12 2004 CL30 CL31 Service Manual 902971 rev 1
12. 84 90 6940 or 49 6103 408 1012 ltaly 39 02 95059 1 Netherlands 31 76 571 4440 Russia CIS 7 095 225 11 15 Spain Portugal 34 93 223 3154 Switzerland 41 1 454 12 12 UK Ireland 44 870 609 9203 Asia India 91 22 5542 9494 Japan 81 45 453 9220 China 86 21 6865 4588 or 86 10 5850 3588 Other Asian countries 852 2885 4613 Countries not listed 49 6184 90 6940 or 33 2 28 03 20 00 Heraeus Megafuge11 Service Manual 11290095 4 2 BIOLOGICAL RISK Most of the safety problems related to appliance maintenance are due to human errors caused by tiredness lack of attention negligence incompetence and more frequently than you might think as a consequence of extreme familiarity with biological risk attitudes which bring to underestimate the risk of exposure to pathogens It is not possible to carry out effective techniques of biological risk containment without taking into account previous attitude of final user Any prevention and biological risk containment program has to be based on correct information and training aimed to make all people concerned adopt ways of acting so that risk of auto contamination and contamination of working area is reduced to the minimum Potential exposed people directly or no directly concerned in lab activities are usually researchers lab technicians but also cleaning staff maintenance personnel no technical personnel employees storekeepers drivers caretakers etc occasional visitors
13. CAT n DESCRIPTION 25535010 Tool to open the unit without power 11202979 Tool to remove the rotor 86005398 Grease for buckets ee Fig 19 Mains switch Keypad membrane Megafuge 11 Keypad membrane Sorvall T1 Display board Lid Assy 85240195 Latch strike hook Lid hinge oo 26962012 Gas spring Centrifugation bowl chamber Bowl gasket Bowl Motor gasket __ 11200593 Centrifuge feet 11201653 Inner plastic part of the lid Heraeus Megafuge11 Service Manual 11290095 27 Electronic rack spare parts ee Fig 20 DO Fig 20 Fig 20 Fig 20 O Fig 20 O Fig 20 Y Fig 20 AS doesn t contain eprom ig 20 Fig 20 ig 20 lo 85481424 Electronic rack kit of components 230V 39903581 uP PWR board 230V 86004585 Contactor 230V 86001432 85481425 Electronic rack kit of components 120V 39903582 uP PWR board 120V 86004598 Bridge rectifier 120V 86004586 Contactor 120V 86001432 A 11250221 EPROM programmed Heraeus Megafuge11 Service Manual 11290095 28 1 1 Motor spare parts Reference CAT n DESCRIPTION Qty ee Fig 21 11250172 Shaft accessory Kit Fig 21 Fig 21 O Springwasher Fig 21 Plastic Centering device LL Fig 21 6 ORing J 1 Fig21 O 39902739 Imba
14. HEY HAVE BEEN STRONGLY TIGHTENED Heraeus Megafuge11 Service Manual 11290095 17 Centrifuge bowl removal see Fig 11 Remove the spring pin from the gas spring Remove the bowl gasket and unscrew the 3 screws from the centrifugation chamber top Remove the bowl motor gasket O Remove lifting up the centrifugation bowl ONE Imbalance sensor replacement see Fig 12 Remove the bowl see paragraph 0 UN The detector is located on the motor counterweight N B Unscrew the 2 screws and remove the sensor Unplug the wire harness from the uP PWR board J4 Replace the sensor in the same fashion reversing the steps Perform the sensor calibration Er ee D Motor replacement see Fig 11 Remove the front panel see par 0 Remove the uP PWR board Remove the spring pin from the gas spring Remove the bowl gasket and unscrew the 3 screws from the centrifugation chamber top Remove the bowl motor gasket Remove lifting up the centrifugation bowl Disconnect the motor wire harnesses Encoder J7 uP PWR board Imbalance sensor J4 uP PWR board Temperature sensor J8 uP PWR board Motor windings from the contactor 8 Unscrew the motor fixing screw located on the centrifuge basement plate 9 Unscrew the 4 screws Allen key number 4 to separate the motor from the counterweight 10 Lift the motor up 11 Replace the motor in the same fashion reversing the steps
15. UU SS RE Check jumpers ST2 and ST3 on uP PWR board as described in par 3 1 6 Check the rotation direction of the motor IT MUST BE COUNTERCLOCKWISE Heraeus Megafuge11 Service Manual 11290095 18 Speed sensor and shock absorbers replacement see fig 13 1 Remove the bottom flange unscrewing the 5 Phillips screws 2 Remove the encoder disk unscrewing the screw 4 and the elastic washer 3 Remove the Hall effect sensor removing the 3 screws 10 11 12 4 Unscrew the 5 shock absorbers 5 Remove the flange unscrewing the 3 screws 6 Replace the flange and the shock absorbers reversing the steps 7 Replace the sensor reversing the steps 8 Replace the encoder disk reversing the steps A Screws Q O 10 must glued using Loctite 243 Fig 13 Heraeus Megafuge11 Service Manual 11290095 19 Lid latch assembly The latch assembly consists of the handle two latches 2 switches a linkage a locking solenoid and a reed relay The cover strikers engages the latches and when the latch is locked in the closed position disengage the two switches The solenoid when is not activated locks the linkage movement The switch senses the status of the cover open closed the reed relay senses if the handle and the linkage is locked Replacement of the lid latch assembly 1 Open the lid Remove the front panel unscrewing the five screws see Fig 11 and disconnect the mains switch wires t
16. agents visitors etc and in case of accidents or disasters rescue service firemen stretcher bearers doctors policemen civil defence etc Technical organisational and procedural measures for biological risk containment according to Art 79 of D L 626 94 must include Evaluation of the danger level and quantity of biological material handled A careful planning of working process to reduce or avoid the use of harmful pathogens and to reduce the number of exposed people The choice of technical measures of protection collective and individual as well as hygienic ones to prevent an accidental spreading of biological agents out of working place Arrangement of suitable procedures and systems for conservation handling collecting and transporting inside and outside working place safe discharge of biological material used and periodic check of an eventual presence of pathogens inside working place To satisfy partly requirements mentioned before Thermo established a Declaration of Decontamination which must be filled in by final user before sending the centrifuge to a Technical Assistance Centre The principle that inspires this declaration is awareness that user only knows what has been put into the centrifuge and who handles these substances only is able to choose and use suitable product for decontamination Obviously this assumption of responsibility by final user does not relieve maintenance personnel of adopting protection
17. display will show 3 Memory Reset Keep pressed simultaneously 8 sec the buttons Pulse and SPEED A The default imbalance level 350 is loaded A After a memory reset is mandatory to proceed with the imbalance calibration 4 Solenoid test Pressing the button user s program 2 the solenoid will be powered 5 User s programs reset Pressing the button user s program 4 the User s AND programs will be cleared 4 6 Imbalance calibration menu Press the Start button to access the Imbalance calibration menu 7 Exit from Diagnostic and calibration Program Press the button Stop to exit from Heraeus Megafuge11 Service Manual 11290095 24 Imbalance Calibration 1 At power on while the buzzer is activated press simultaneously the buttons acceleration and deceleration 2 The display will show 3 Second menu Press the Start button to access the Imbalance calibration menu 4 The display will show 5 Install the rotor T41 unloaded and press the Pulse button The first calibration cycle 2500rpm 50 sec will start A The rotor must be balanced The difference in weight between buckets should be maximum 0 5 grams 6 Atthe end of the run the imbalance level measured is displayed A For a balanced rotor the value detected shall be lt 200 If the value is gt 200 and the rotor Is balanced the sensor could be defective 7 Load bucket n 1 with the calibrated weight 17 grams
18. e till speed is zero To erase the message open the lid turn the power and a 4 minutes timeout is expired switch off and turn the power switch on Power was interrupted during a run Press any keyboard button to erase this message At power off the rotor will coast to a stop Note if Error 01 has been detected and not cleared as above described the alarm reset is possible only after a safety time of 30 minutes Speed 0 RPM at power ON Wait for rotor to stop The rotor will coast to a stop Press any keyboard button to erase this message Lid open in running mode Wait for the centrifuge to stop The rotor will brake to a stop Press any keyboard button to erase this message Motor Over temperature Wait for the centrifuge to stop OR Press any keyboard button to erase this message Lid lock error Wait for motor cooling down The rotor will brake to a stop Electronic failure To erase the message turn the power switch off and turn All controls are disabled the power switch on Lid open at start Press any keyboard button to erase this message The centrifuge doesn t start if the lid isn t Close the lid and press properly closed START Imbalance Wait for the centrifuge to stop The rotor will brake to a stop Press any keyboard button to erase this message Verify that a balanced load is installed Inspect the rotor and rearrange the tubes or add additional tubes with fluid to balance the rotor Heraeus Megafuge11 Serv
19. he Flat Cables the display power supply cable the protective earth wire Disconnect the lid latches assembly from the uP PWR board J10 Unscrew the four Phillips screws Remove the lid lock mechanism support Reassemble reversing the steps with the new lid latch ensuring the alignment to get the proper latching rab Gs Fixing Phillips screws Solenoid micro switch Lid micro switches Solenoid amp Lid handle Heraeus Megafuge11 Service Manual 11290095 20 Replacement of lid latch spare parts Fig 15 5 1 1 Micro switches replacement amp Disconnect the Fast on connectors Remove the two screws that secure the switch in place Reposition the new switch securing it with the screws Connect the Fast on connectors Test the lid latch use a multimeter to measure resistance across the switch leads Switch should read open when the cover is open closed when the cover is closed Switch should read open when the cover is open closed when the cover is closed The reed relay should read closed when the solenoid is activated UE a eI ess 5 1 2 Latch replacement 1 Remove the lid latch assembly as described in par 0 2 Unscrew the nut 9 3 Remove the mass 4 Extract the screw 5 Unscrew the nut O 6 Remove the cam 7 Unscrew the nut underneath the cam 8 Extract the screw 9 Remove the latch 10 Replace the latch in the same fashion reversing the
20. ice Manual 11290095 16 5 REPLACEMENTS PROCEDURES A BEFORE ANY REPLACEMENT PROCEDURES CAUTION DISCONNECT THE MAINS REMOVING THE POWER CORD FROM THE CENTRIFUGE Front panel removal Removal of the control panel allows access to many internal components Follow this procedure to remove the front control panel 1 Unplug the unit Remove the 5 screws from the top and bottom edge of the front panel 3 Disconnect the wire harnesses the mains switch wires the Flat Cables the display power supply cable the protective earth wire a The two Flat Cables can be disconnected either from the uP PWR side connectors P1 and P2 or from the front panel it is better to disconnect all of them from the same side to avoid D 5a CN errors during refitting Disconnect the E display power supply cable red black 7 from the front panel et Ey i u Fig 11 Lid replacement see Fig 11 Open the lid Remove the spring pin from the gas spring Unscrew the five screws connecting the lid to the lid hinge Remove the lid Replace the lid in the same fashion reversing the steps i Es FIXING SCREWS MUST BE CONSIDERED AS A COMPONENTS OF MECHANICAL SAFETY CHECK CAREFULLY THAT T
21. isruption or drive failure To avoid dangerous consequences a safety envelope clearance around the unit must be respected Heraeus Megafuge11 Service Manual 11290095 7 Component layout Inlet appliance G Lid lock solenoid Imbalance sensor Display assembly keyboard Asynchronous motor O uP PWR board Centrifugation chamber Gas spring Mains front end rack 1 QT spe J A Ic mm mm PS y e ul Wu pa ut Y Ji 9 Fig 3 Appliance inlet and fuses holder G Protective conductor terminal Terminal block Fast on Mains filter Mains transformer Heraeus Megafuge11 Service Manual 11290095 8 Functional principles The microprocessor system controlling the Megafuge11 ensures the following functions Operator interface management The operator interface composed of a LED display and a keyboard enables programming of the centrifugation parameters and visualisation of operating conditions in real time Rotation speed servo control management From a tachometer signal the microprocessor calculates in real time the controls to be applied to the power components to perform as programmed rotor type identification maximum speed restriction accele
22. lancedetector 1 Fig21 O 11200508 Motor Counterweight LL 860053988 Grease See Fig 22 11250204 Fig 22 O Fig 22 Fig 22 Fig 22 Fig 22 Setofscrews 4 Jj Heraeus Megafuge11 Service Manual 11290095 29 Lid latch spare parts S ES E e E gt 3 Li 0 Fig 23 Fig 23 85481432 Lid Latch assy Fig 23 86001406 Lid micro switch Fig 23 O 11201185 Fig 23 39900043 Solenoid switch Reed Relay Solenoid Solenoid Fig 23 85440187 Solenoid Spring 1 Fig 23 11250207 Spring 0 0 0 4 Fig 23 11201156 Lockingcam 1 2 Fig 23 O 85440000 X Hande 2 1 MI 1 Heraeus Megafuge11 Service Manual 11290095 90 Mains front end spare parts 39902981 Mains front end rack kit of components 230V Fig 24 86004803 Toroidal transformer 230Volt II Fig 24 86003248 Line filter 230Volt II Fig 24 86000775 Mains inlet and fuse holder 1 10 39902587 Mains front end rack kit of components 120V 1 Fig 24 39903078 Toroidal transformer 120Volt II 86003256
23. om the motor to the inverter This results in current flowing from the inverter into the DC bus capacitors Because this energy cannot flow back into the AC supply it must be stored in the capacitors or dissipated through a brake resistor if the voltage will rise over the defined safety level e A E EM 1 5 DC BUS J E Fig 6 Heraeus Megafuge11 Service Manual 11290095 10 Electronics 3 1 4 Generality Electronic consist in two boards uP PWR board equipped with 16bit micro controller located behind the front panel see Fig 2 n The centrifuge management program is stored EPROM memory configuration data are stored in non volatile RAM User interface display and a keyboard attached directly on the rear of the front panel see fig Fig 2 0 The imbalance sensor is fixed on motor counterweight trough elastic suspension see Fig 2 number 0 it detects motor vibrations usually caused by improper rotor load 3 1 5 Differences between models 230V 120V The main difference between 230V and 120V is on the input stage of the motor power control As mentioned in par 3 1 3 the single phase rectifier in case of 120V is used in the voltage doubler configuration The bridge rectifier is onboard for the 230V version located on the electronic rack see par 0 for the 120V So two different uP PWR boards are used 3 1 6 Micro Process
24. or PWR board 3 distinct areas can be identified on this board Each of the 3 areas has its own power supply Insulation between the different parts is ensured by the use of opto couplers Fig 7 A d D SR Mh m IDUAN CM TlUas2324ng8 Le Bec Ob fM SE II AF J amp 5 py 18 ee mr AREA 1 It includes the microprocessor the EPROM the RAM memory and the backup battery The power supply for this part of circuits is 5 Vic Heraeus Megafuge11 Service Manual 11290095 11 AREA 2 It consist in sensors interface and signal conditioning circuits including the Opto couplers which improve the level of noise immunity The power supply for this part of circuits is 12 Vic Note In case of replacement of MOTOR or uP PWR it is mandatory to have the proper jumpers configuration The motor with magnetic speed sensor M REQUIRES 7 y 1 Jumper ST2 z Closed short circuit J6 1 1 Jumper ST3 Open TP JB AREA 3 AN CAUTION RISK OF ELECTRIC SHOCK Includes all the power circuits and it is directly connected to the mains Main function are DC bus 320 Voltpc the incoming AC power is rectified and filtered to supply the 3 phases motor inverter The optical insulation barrier which provides protection against electric shock between life parts and microprocessor circuits Three phase inverter consisting of six IGBT one package module and his control logic circuit Motor brake IGBT 3 1
25. orget the plastic insulation foil Mylar amp between the chassis and the board RA n TQ va uv ha re O A HI HU O et j ol O O Fig 17 EPROM replacement It is not required to remove the P PWR board for the EPROM replacement A ATTENTION STATIC SENSITIVE Proper handling and grounding precaution required FOR EPROM REPLACEMENT USE ONLY THE SUITABLE EXTRACTOR BB di DURING REPLACEMENT OPERATION KEEP THE EPROM as PARALLEL TO THE SOCKET gt INSERT THE NEW EPROM KEEPING THE KEY SLOT TOWARDS THE MICROPROCESSOR ALWAYS USING THE EXTRACTOR Unplug the unit Remove the front panel see par 4 1 Replace the EPROM Perform the Memory Reset and the Imbalance calibration as described in par 6 SAID Heraeus Megafuge11 Service Manual 11290095 23 6 DIAGNOSTIC AND CALIBRATION PROGRAM The centrifuge has a built in diagnostic program which can be accessed by pressing a combination of buttons at power on Access to the Diagnostic Menu 1 At power on while the buzzer is activated press simultaneously the buttons acceleration and deceleration ramps 2 The
26. ration and braking profiles rotating speed g force time Management of the safety devices The control system manages all the safety devices lid locking system imbalance detection system zero speed detection system motor over temperature detection system over speed control KEYBOARD DISPLAY QA LOCK 7 x Hi A li a 2 88 69888 88 Sets ANE EP Ve Xf e TL E oe _ EN o sal FLAT CABLES 17 4 MICRO INT M My EAR p S i t1 MICRO WII S a j 2 LECTROMAGNET 1 E ss Geck ET EMP S U El LOAD IMBALANCE g a a SENSOR c JG EE l n MAINS MOTOR LP l CN l TU FT T C2 Lo ee 88880 ee H Fig 4 Heraeus Megafuge11 Service Manual 11290095 9 Management of the induction motor 3 1 1 Introduction The Megafuge11 is equipped with an asynchronous 3 phase induction motor During operation the control electronics generates a system of sinusoidal 3 phase voltages variable in amplitude and frequency During the braking phase the energy generated by the motor is dissipated through a resistor 3 1 2 The motor
27. steps 5 1 3 Reed relay 13 Remove the two plastic screws Unsolder the wire harness Replace the sensor reversing the steps Test the reed relay use a multimeter to measure resistance across the sensor The reed relay should read open when lid is open and the unit is not powered The reed relay should read closed when the solenoid is activated during centrifugation NE 5 1 4 Solenoid 14 Remove the lid latch assembly as described in 0 Disconnect cutting the wiring to the solenoid Unscrew the two fixing screws latches side Slide the locking plunger out Replace the new solenoid reversing the steps CONS Heraeus Megafuge11 Service Manual 11290095 21 6 Verify that the locking plunger is moving freely Electronic rack and Mains front end rack removal see Fig 16 On the Electronic rack are located the uP PWR board the motor contactor and the brake resistor behind the uP board Remove the uP board to access the brake resistor On the mains front end rack are located the mains inlet socket with fuses the line filter the terminal block and the mains transformer To replace one of those components the rack must be removed
28. tors dnd e 32 P Appendi Ma A A A A ie 33 Warins diagtati 230 V versomno0 60L EE 33 Marine dastam 20V Version GO AZ LS dins 34 Heraeus Megafuge11 Service Manual 11290095 3 1 INTRODUCTION Purpose This manual contains maintenance instructions for Meg afuge11 centrifuges and is intended for use by a qualified maintenance or service technician We suggest reading also respective Operating Manual It is organised to provide maintenance personnel Thermo or authorised service organisation with basic data and information on the theory of operation to assist in troubleshooting it outlines parts replacement and calibration procedures for putting the centrifuges back into service Should a specific maintenance problem arise which is not covered in this manual please ask the authorised service organisation or contact our division indicated here below Concerned units 75004410 HERAEUS MEGAFUGE 11 230V 50 60Hz 75004411 HERAEUS MEGAFUGE 11 120V 60Hz 75002381 SORVALL T1 230V 50 60HZ 75002382 SORVALL T1 120V 60HZ Note Sorvall T1 models differ from Megafuge 11 only for the keypad membrane However it is always possible to have copies updated or revisions of this manual contacting our division Thermo ELECTRON CORPORATION Technical Service Address North America 1 866 984 3766 Europe Austria 43 1 801 40 0 Belgium 32 2 482 30 30 Finland 358 9 329 100 France 33 2 28 03 20 00 or 33 1 6918 7777 Germany 49 61
29. ug v AOE indui 132211 indui Jepoaua ALT elf LLP B JT 1015158 Burjeiq 0 008 ETETEN ER m Cu x E g E IRC IT TOUT gi 4 SHL amp 5 sla HO 0 38 14 38 3 1 FT PEOSZEZES I pTT ID OD DO U CO OU D T NENIE waan AZ LA 74 cun JOJOLU y 0 Fi dans amod Jaap pieoq ay AG Io ovy AS OL Aejdsip pal PIEOJ 10 OWA rc indu HOA El ndino Gu Cd ld LI cr n 8 agod dulaj CR Josuas 83UEJEJLU Fr Fig 10 Os Heraeus Megafuge11 Service Manual 11290095 4 DIAGNOSTICS AND REPAIRS Introduction The Megafugel 1 has some built in functional tests which facilitate checks such as for the tachometer generator and lid lock solenoid In case of anomaly the display shows error codes combined with an audible alarm Messages At power on The TIME display shows the CENTRIFUGE MODEL M11 The SPEED display lights all the segments 88888 The TEMPERATURE display shows the PROGARM EPROM REVISION A B C Error codes and messages When a problem is detected an error code combined with audible alarm is displayed According to the severity of the anomaly the run can be aborted in this case the centrifuge stops automatically For the details refer to the following table REASON COMMENTS EXIT CODES Incorrect speed measurement Wait for rotor to stop bd The rotor will brake to a stop Wait for the 4 minutes timeout Lid opening is impossibl
30. w 902561 i Blow i SW19 e A i LC1K0610M7 Imbalance sensor blue Blue 903212 903208 3 green Green 903212 red Red 903212 902564 SW17 2 brown Brown B D doe 902573 100n 470hm 90 7 2 Rifa PMR 209 MC 3 blue 902573 Brake resistor 902571 ellow O 100 ohm CMC34 TRANSFORMER Orange 5 100W e4x 2rteoda7ds43210 LL ky bb ellow o Reed P1 e Switch J1 keyboard and pilot leds Display 10 5V AC Motor 15V 12VDC Red J3 not used Black Power rectifier 3 Blue E ise Solenoid Imbalance Motor sensor CPU and Power control _ 230V Black a white not used Lid switch solenoid brake J13 b s 5 switch and solenoid Compressor Line resistors N S Hidiswiteh Motor command command er Ext Power Encoder thermoswitch 12V J10 not used rectifier Ji J16 hito Hil 902554 nd A Se RN 902565 Drawn by Model 220 230V 50 60 Hz A Frollo Pa Verified by C3 Eyelet Display and Keyboard A Frollo Faston Braided sleeve Approved by A 902587 The reproduction in whole or part of this design is forbidden All rights are reserved to Jouan Italia S r l CL30 CL31 Service Manual 902971 rev 1 33 Wiring diagram 120V version 60Hz 2x6 3AT fuses Line filter Main switch Brown Brown T zm 903208 1 gt Seite Brown STO Brown A 1 E S S 9025
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