service manual
Contents
1. gt CONTROLLER BOARD RS 232 Motor Drive Interface RS 232 Balance Interface RS 232 Computer Interface Display Interface and power Buzzer Keypad connector Microprocessor Memory and DUART for computer amp balance interface 5V Switching Power Supply B C 7 rane oe 0 oma Et _ 25 toto du 2 Oooo S Bong goog goog 1 4 5 BH 5 ee 4 M SARA uuum EI i z AN H m lt gt D z ans inn nim Je Pe ey 29 Barm 7 gt Fee E 3 g ELE ber id idis FEM CENE i 8 S i i got m i situ at 1 iw TROUBLESHOOTING Repairs on this unit are confined to the units drive and controller PC Board and or drive motor assem2. RPM The controller display should show 600 for each of the drives connected Attach a dispensing wand to the drive unit DB9 port Then activate the auxiliary switch on the dispensing wand and the drive should start If a drive isn t connected or there is a problem with the drive an error code will be displayed CODES NONE No response from drive Drive not connected or not communicating 5 Timeout ER6 No encoder pulses ER7 Excessive encoder pulses ER8 Incorrect motor response 9 Motor current error ERA Bus voltage error 7 Using a hand tach verify that the connected drives are running at 600 1 RPM Release the dispense wand switch and motor should stop 8 Enter exits the RPM mode Drive Only Proceed to Step 12 9 Turn OFF drive drives 10 Turn drive drives ON and verify that there are no error messages 11 Turn drive drives OFF and unplug and disconnect controller 3 0 Safety A HI POT TEST With a sensitivity setting of 5 mA apply 1900 VDC 77310 01 only Hot lead Black to Ground for 60 sec B LINE LEAKAGE TEST 5mA MAX C GROUND RESISTANCE TEST 5 ohms MAX 23 Output Input Display SPECIFICATIONS Speed Maximum torque output Speed regulation all conditions Remote contact closures Dispense volume Dilute volume Supply voltage limits 115 VAC 230 VAC Nominal current 115 VAC 230 VAC Installation category Remote input Construction Contr
3. 5 cp Ne 10 REPAIR 4PROGEDU RES rte eio teet 11 REPLACEMENT PARTS EDS TING x cients cet oid se nd fait uide oderat opido oa od 19 CHECK OUT PROCEDURE 21 SPECIBIOATIONS t e Een Eh RO eb aen ente 24 ACCESSORIES e tetas theod ute maU e 25 INTRODUCTION 2 Service for this product is performed at three levels the customer distributor COLE PARMER factory depot repair This manual describes dis tributor COLE PARMER service procedures Customer service procedures are described in the operator s 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 Distributor COLE PARMER repair is limited to replacement of modules as detailed in the replacement parts list section The repair procedures section details disassembly and assembly procedures After repair the product should be calibrated and checked for proper performance Please refer to the operator s manual A 1299 0780 for A Applications Data B Product Description C Installation D Set
4. DISASSEMBLE CONTROLLER UNIT B Replace the cable 1 Cable from PCB J5 2 Cable to PCB J6 C Secure Display PCB with four screws D Follow the steps outlined in ASSEMBLE CONTROLLER UNIT TO REMOVE KEYPAD A Follow the steps outlined in DISASSEMBLE CONTROLLER UNIT B Remove cable from PCB J7 C Peel keypad from enclosure D Affix new keypad to enclosure TO REMOVE PCB ASSEMBLY A Remove the four screws from the printed circuit board B Remove PCB Assembly C Remove all cables and wires from PCB TO REPLACE PCB ASSEMBLY A Follow the steps outlined in DISASSEMBLE CONTROLLER UNIT B Replace PCB assembly C Note wiring of chassis as follows 1 RED and BLACK of Display PCB to J6 2 Ribbon cable of Display PCB to J5 3 Cable of keypad to J7 D Follow the steps outlined in ASSEMBLE CONTROLLER UNIT REPLACEMENT PARTS LISTING The following is a list of stockable main control PCB assemblies and their reference schematic diagrams for all indicated models MODELS MODEL PCB REFERENCE SCHEMATIC 77310 00 E 2429 0003 E 2306 E 2323 0001 E 2321 77310 50 E 2429 0003 E 2306 E 2323 0001 E 2321 77340 00 E 2429 0003 E 2306 E 2323 0001 E 2321 77340 50 2429 0003 2306 2323 0001 2321 77310 02 2323 0001 2321 77310 01 2429 0003 2306 OTHER REPLACEABLE PARTS Description Part Number 19 Line cord B 3115 115V Line co
5. occurred Check voltage selection switch for proper voltage Check pump and or motor drive system for binding Check with a known good motor Check AC supply voltage use approved balances replace controller board check balance owners manual check replace cable replace controller board return unit DANGER Never remove the cover from the pump drive when power is present AC and DC power in the pump drive can cause serious injury or death Ensure that the pump drive is disconnected from the power source before removing the cover for maintenance Allow ten minutes for the capacitors in the power supply to discharge before proceeding TO DISASSEMBLE DRIVE UNIT PROCEED AS FOLLOWS 12 A Disconnect AC power B Remove and retain the four screws from each side of the pump drive cover C Remove the cover by sliding it straight up TO REASSEMBLE DRIVE UNIT PROCEED AS FOLLOWS A Slide on cover B Install the four pan head screws on each side of the unit s cover TO REMOVE PCB STACK ASSEMBLY A Remove fuse B Remove the two pan head screws on the I O panel at the rear of the chassis C Remove the four screws from the lower printed circuit board D Remove PCB Stack Assembly E To remove PCB slide it forward and lift up F Remove all cables and wires from PCB TO REPLACE PCB STACK ASSEMBLY A Follow the steps outlined in DISASSEMBLE DRIVE UNIT B Replace PCB Stack assembly C Note wiring o
6. 0 1 A2 1995 Safety EN50081 1 1992 EMC Emissions and EN50082 1 1992 EMC Immunity ACCESSORIES 25 Description Part Number 10 ft 3 m RJ 12 cable 77095 03 15 ft 4 6 m RJ 12 cable 77095 04 Footswitch 07595 40 Dispenser handle for 1 to 4 pumps 77310 05 Dispenser handle holder small V base 08024 55 Dispenser handle holder large V base 08024 56 PTFE tubing weights 77310 03 Glass dispensing tip w Luer lock for 3 16 in and 1 4 in ID tubing 77310 04 EASY LOAD II pump head for high performance precision tubing 77200 62 EASY LOAD 11 pump head for precision tubing 77200 60 Mounting hardware 2 pump heads 77200 02 Y connectors for use with L S tubing size L S 13 L S 14 10 pk KYNAR 30703 90 L S 16 20 pk Polypropylene 06295 10 L S 15 L S 25 20 pk Polypropylene 06295 20 L S 17 L S 24 20 pk Polypropylene 06295 30 L S 18 L S 35 L S 36 20 pk Polypropylene 06295 40 Stands Frame rods small 08024 22 Frame rods large 08024 23 Equipment clamp small 08024 40 Equipment clamp large 08024 41 Frame clamp 08024 28 V Base small 08024 55 V Base large 08024 56 26
7. 77310 00 77310 50 77340 00 77340 50 77310 02 77310 01 SERVICE MANUAL MODELS L S Digi Staltic Pump System for high performance precision tubing 115 230 VAC L S Digi Staltic Satellite Drive for high performance precision tubing 115 230 VAC L S Digi Staltic Pump System for precision tubing 115 230 VAC L S Digi Staltic Satellite Drive for precision tubing 115 230 VAC L S Digi Staltic Pump System Controller L S Digi Staltic Satellite Drive with no pump heads 77310 00 and 50 are supplied with two each 77200 62 pump heads 77340 00 and 50 are supplied with two each 77200 60 pump heads 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 0802 EDITION 02 TABLE OF CONTENTS INTRODUCTION e 2 SAFETY CONSIDERATIONS 4 FUNCTIONAL DESGCRIFETION ind cue pm acier nl Cs i a 5 DRIVE BOARD ueteres Ct ctc de ci ett 6 BOARD HD 8
8. bly Where possible swap known good parts to localize and isolate the problem The following is a list of possible problems and remedies VERIFY AC POWER IS OPERATIVE UNIT DOES NOT TURN ON NO SEVEN SEGMENT DISPLAY 1 fuse blown 2 power cord not connected properly 3 A C power switch failure 4 unit connected to dead outlet UNIT BLOWS FUSES 1 wrong voltage selection 2 motor drive failure 3 defective drive board 4 wrong fuse installed DRIVE UNIT DISPLAY 0 1 RJ12 cable not connected properly 2 controller RJ12 port is defective replace fuse check amp replace replace switch assembly verify supply is HOT check proper voltage switch position check using known good motor return replace drive board check fuse type and rating check replace cable try another pump replace controller board MOTOR WILL NOT RUN DRIVE UNIT DISPLAYS A PUMP 1 defective keypad 2 defective drive board 3 defective encoder NO REMOTE OPERATION 1 defective controller board 2 external cable not connected properly return replace keypad return replace drive board return replace motor assembly return replace controller board check replace cable FOR ADDITIONAL INFORMATION REGARDING YOUR UNIT PLEASE REFER TO THE FOLLOWING A 1299 0780 Operator s Manual REPAIR PROCEDURES DISPLAYED ERROR CODES COMMUNICATIONS ERRORS ERROR ENTER CONTINUES COMMUNICATION ERROR 7 72123 1 check
9. e of the motor C Refer to Figure 8 and remove the brush caps D Rotate each brush retainer so it lines up with the groove in the brush holder Remove the brushes E Measure the length of the brushes If either brush is less than 0 30 in 7 6 mm long they both need to be replaced Always replace them in pairs CAUTION Excessive commutator wear or bridging between commutator segments can cause excessive current through the controller circuit and damage to the dispenser F Inspect the commutator for wear and dirt If the commutator segments are worn replace the motor If there are dark tracks where the brushes contact the commutator clean with isopropyl alcohol G Install the brushes into the brush holders and rotate the retainer to secure the brushes Reinstall the brush caps H When the motor has been reassembled refer to Belt Replacement to reassemble the pump drive PIVOT MOTOR TO GAIN ACCESS TO OTHER BRUSH HOLDER 0 3 inch 7 6 anu m EH Figure 8 Inspecting and Replacing Brushes TO DISASSEMBLE CONTROLLER UNIT PROCEED AS FOLLOWS A Disconnect AC power B Remove and retain the four screws from the under side of the controller C Remove the cover by sliding it straight up TO REMOVE DISPLAY PCB A Follow the steps outlined in DISASSEMBLE CONTROLLER UNIT B Remove the four screws holding the PCB to the cover C Remove cables TO REPLACE DISPLAY PCB A Follow the steps outlined in
10. e pump number The controller display should display the appropriate drive type DIGI For Example if there was only 1 pump 77310 01 plugged into the controller Pump 1 location the display on the controller should display the following 2 1 DIGI 2 NONE 3 NONE 4 COM PASS KEYPAD RPM DISPLAY ERASE EN CONTROLLER Drive Only Proceed to Step 7 77310 02 only If only one drive is being used leave the drive on and remove RJ12 cable from the Pump1 location and repeat on RJ12 ports Pump 2 Pump 3 and Pump 4 Verify the drive s seven segment display shows 8 then the correct number for each RJ12 pump port and that the controller reports the proper drive COM should have PASS indicating the Balance and PC ports are operating correctly If there is a failure FAIL will be displayed 77310 02 only Activate the KEYPAD test by pressing the arrow just below KEYPAD Then press each key and verify the key was pressed by observing the controllers display Press the cancel stop button twice to exit keypad test PRESS EACH KEY ONCE PRESS CANCEL UP ARROW 1 TWICE TO EXIT Pis 77310 02 only Activate the DISPLAY test by pressing the arrow just below DISPLAY All segments should fill in 77310 02 only Activate the ERASE by pressing the arrow just below ERASE This will erase any programs in memory DRIVE 6 77310 01 only Activate the RPM test by pressing the arrow just below
11. es when lit power and numerically indicates the port from which its plug into the controller This RJ 12 port supplies power to and RS 232 communication with the controller The drives also have a DB 9 connector for remote start stop input and two contact closure outputs The pump systems are supplied with two L S Easy Load Il pump heads No operator controls other than the on off switch and contact closure switch are provided The drives are driven by permanent magnet DC brush motors using optical tachometer feedback for accurate speed control The unit is dual 115 230 VAC voltage 115V line cord is supplied DRIVE BOARD A Input and Bus Voltage B PWM Motor Control Bridge C Dynamic Break Resistors D I O and Earth Grounded Power Supply E 5V Switching Power Supply F Microprocessor and Encode Decode Circuitry ES ETETETT mu Ej ipii UJ e rn er ye ok BES HE os SSS gf 18 0 or so eden Bornont ht aga m ew Mr Dy xi FONS YEMES 1E
12. f chassis as follows 1 WHITE of AC power switch to J6 2 BLACK of AC power switch to J5 3 RED of drive motor to M1 4 BLACK of drive motor to M2 5 GREEN YELLOW of chassis ground to J4 6 Ribbon cable from Display PCB J1 7 Cable from Motor Encoder J2 D Follow the steps outlined in ASSEMBLE DRIVE UNIT TO REMOVE SEVEN SEGMENT DISPLAY PCB A Follow the steps outlined in DISASSEMBLE DRIVE UNIT B Remove the two nuts washers holding the PCB to the chassis C Remove ribbon cable REPLACE SEVEN SEGMENT DISPLAY PCB A Follow the steps outlined in DISASSEMBLE DRIVE UNIT B Replace cables 1 Cable from PCB Stack assembly J1 C Secure Display PCB with two nuts washers D Follow the steps outlined in ASSEMBLE DRIVE UNIT TO REMOVE BELT A Follow the steps outlined in DISASSEMBLE DRIVE UNIT B Refer to Figure 7 and loosen but do not remove the two nuts that secure the motor to the top of the motor mounting brackets NOTE Be careful when working near the fan end of the motor The fan blades are sharp C Pivot the motor toward the pump and remove the belt from around the motor pulley D Remove the belt from around the pump pulley TO REPLACE BELT A Install the replacement belt around the pump pulley and around the motor pulley B Pivot the motor so the belt is taut and secure the motor in position by tightening the loosened nuts loosened just enough to hold the motor C Test belt tensio
13. h two 1 59 Easy Load Il pump heads with tubing sets provide the actual pumping action The control console is a basic I O computer for operator interface and pump coordination The operator is guided through a series of menus to operate and to program the unit The LED backlit two row by forty character alphanumeric display and four soft keys help the user through all the necessary control steps A total of 20 membrane keys including the numbers zero through nine also facilitate the operator s actions An HC11 based microcontroller scans the keypad communicates to the LCD display module and communicates with the attached satellite drives The users program information is stored indefinitely in an EEPROM The pump powers the control The controller communicates with the satellite drives via an RS232 port The controller is the master and hub of a star configured system The on chip asynchronous serial interface of the microcontroller is multiplexed to four RJ 12 phone jack ports on the controller TD Transmit Data RD Receive Data plus the control signal RTS Request To Send are implemented in the controller and satellite drives The controller can broadcast system commands for example go and stop to all the drives for synchronization The drives can request to be heard by the hub with RTS hand shaking A baud rate of 19200 is used The drives have an on off switch and a seven segment display The seven segment display indicat
14. n by pressing on the belt midway between the pulley The belt should flex approximately 1 8 in 3 mm D If belt tension is correct tighten the nuts securely If tension is not correct loosen the nuts and repeat E Follow the steps outlined in ASSEMBLE DRIVE UNIT TO REPLACE BELT NOTE Inspect the belt to see if it is broken or has missing teeth If it is broken or worn it needs to be replaced A Refer to Figure 7 and loosen but do not remove the two nuts that secure the motor to the top of the motor mounting brackets LOOSEN TWO NUTS Figure 7 Replacing the Belt Brush Replacement Exact motor brush and commutator life will depend on duty cycle and motor operating speed Inspect the brushes every six months or after 2000 hours of operation whichever occurs first Replace brushes if they are less than 0 30 in 7 6 mm long Inspect the commutator when the brushes are replaced and clean if necessary DANGER Never remove the cover from the pump drive when power is present AC and DC power in the pump drive can cause serious injury or death Ensure that the pump drive is disconnected from the power source before removing the cover for maintenance Allow ten minutes for the capacitors in the power supply to discharge before proceeding A Refer to Belt Replacement remove the cover and remove the belt from the pulley on the drive motor B Pivot the motor away from the pump to gain access to the brush on the pump sid
15. ol console dimensions Control console weight Pump drive dimensions Pump drive weight Two EASY LOAD II pump heads Environment Operating temperature Storage temperature Humidity non condensing Altitude Pollution degree Chemical resistance Environmental protection Compliance 24 6 to 600 rpm 12 9 180 oz in 0 3 of full speed 28 VDC 1A 28 VAC 1A 0 1 mL to 8000 L Sample 0 1 mL to 100 0 mL Delivery 0 1 mL to 8000 L 90 VAC to 130 VAC 48 Hz to 63 Hz 180 VAC to 260 VAC 48 Hz to 63 Hz 1 7A 0 8A Category per IEC 664 Local level appliances portable equipment etc START STOP 5 VDC 5 mA 40 character x 2 line backlit LCD 22 6 cm 8 9 in wide 16 5 cm 6 5 in deep 2 3 cm 0 9 in front 6 9 cm 2 7 in back in height 1 4 kg 3 0 Ibs 23 4 cm 9 2 in wide 32 3 cm 12 7 in deep 18 8 cm 7 4 in high 9 1 kg 20 Ibs 14 6 cm 5 75 in deep 0 to 40 C 32 to 104 F 25 to 65 C 13 to 149 F 10 to 90 Less than 2000 m 6500 ft Pollution degree 2 per IEC 664 Indoor use lab office All materials withstand standard cleaning solvents Materials used in the construction are a polyester label a combined aluminum motor and paint loc steel controller enclosure and an epoxy based non chip paint finish Withstands general spills and light sprays IEC 529 IP22 Meets UL 508 CSA C22 2 No 14 M91 and EN6101
16. rd B 2938 230V AC Receptacle B 4016 3 1 2 ft 1 1 m RJ 12 cable 77095 02 Seven Segment Display Assembly B 3889 CR Keypad Controller E 2534 Bearing Block Assembly D 3115 CR ON OFF Switch B 1084 0121 Belt A 1341 0006 Small Belt Pulley A 3166 Large Belt Pulley B 2317 Motor Assembly D 3106 0001 Motor brushes 2 B 1238 0056 Fuse B 1115 0043 Rubber feet each A 1390 0004 20 CHECK OUT PROCEDURE 0 00 Test equipment required 0 01 Hand Tach 0 02 Line leakage tester 0 03 Hi pot tester 0 04 DB9 Communication Jumper cable 0 05 RJ12 Cable 0 06 Dispensing Wand 77310 05 or Foot switch 07595 40 0 06 Voltmeter 0 08 Test Unit 77310 02 Only 77310 01 Test Drive 77310 01 Only 77310 02 Test Controller 2 00 Performance CAUTION HIGH VOLTAGE IS PRESENT ON CONNECTORS AND PCB A OPERATION 1 a Switch the voltage selector switch to the proper voltage and plug in the drive b Plug the RJ 12 cable into the rear of the controller 77310 02 labeled Pump 1 2 3 4 and the other end into the rear of the drive 77310 01 c Plug a jumper cable into the Balance DB9 to the PC DB9 ports of the controller 77310 02 linking them together While holding the upper left arrow key on the controller switch the main power on one of the connected drives Release the arrow key and turn on any remaining drives Verify that the display number displays 0 for 3 seconds then 8 for 3 seconds then the drive should display the appropriat
17. sum error 2 framing error 3 overrun error 4 invalid command 5 invalid data 6 incomplete command string 10 no reply from pump drive 11 reply command didn t match request command 12 7 calculated checksum didn t match rx checksum DRIVE ERRORS 1 ENTER CONTINUES DRIVE STOPPED BY TIMEOUT 1 drive cable to controller disconnected bad replace reattach cable 2 defective drive board replace drive board 3 defective controller board replace controller board 2 ERROR ENTER CONTINUES NO ENCODER PULSES 1 encoder cable disconnected bad replace reattach cable 2 defective drive board replace drive board 3 defective motor encoder assembly replace motor assembly 3 ERROR ENTER CONTINUES MOTOR OVER SPEED 1 defective drive board replace drive board 4 ERROR ENTER CONTINUES MOTOR CONTROL FAULT 11 1 Voltage selection switch set to improper voltage ERROR ENTER CONTINUES MOTOR OVER CURRENT LIMIT 1 Current limit is being exceeded ERROR ENTER CONTINUES BUS VOLTAGE LIMIT 1 Voltage limit is being exceeded ERROR ENTER CONTINUES CANNOT COMMUNICATE WITH BALANCE 1 Wrong balance 2 Port isn t working 3 Balance isn t setup and wired correctly 4 External cable not connected properly ERROR ENTER CONTINUES BAD EEPROM WRITE DATA NOT SAVE 1 The controller couldn t write to the EEPROM ERROR ENTER CONTINUES UNKOWN ERROR CODE An error unknown to the controller has
18. up E Operation F User Calibration G User Troubleshooting amp Maintenance H Accessories 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 When servicing any component of this unit make absolutely sure 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 CAUTION Do not inadvertently short any part of the printed circuit card to ground as severe damage will result CAUTION Almost all circuits are referenced to the AC line Powering the unit from a isolation transformer is strongly recommended DANGER Never remove the cover from the pump drive when power is present AC and DC power in the pump drive can cause serious injury or death Ensure that the pump drive is disconnected from the power source before removing the cover for maintenance Allow ten minutes for the capacitors in the power supply to discharge before proceeding FUNCTIONAL DESCRIPTION The Masterflex dispenser pump and diluter system has two major components A tabletop control console provides means for operator programming and control As many as four satellite drives wit
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