Grant OPTIMA RANGE GD100 Service Manual Download Page 19

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R8
10K
(4K7)

390R

R12

T24

T25

PL7/4

IC 3

C2
470

C1
100

D1
1N4006

D2
15V

µ1

+12V

VR1
10K

R13

470R

10K

R3
180K

C8
1

C10
1

R4
100K

100R

220K

DB1

C4
2200pF

2300pF

R10

270K

(180K)

1N4006

220

16V

C5
1000

C6
0

µ1

+5V

IC 1

IC 2

IC 4

OPTO-ISOLATOR

PL7/5

PL7/3

PL7/1

PL7/6

PL7/2

PL7/7

PL5/1

FS 1

FS 2

MAINS

SWITCH

IEC

MAINS

SOCKET

110V UNIT

230V UNIT

LIVE
(smooth wire)

FS 2

NEUTRAL
(ribbed wire)

HEATER

NEON

R9
270K
(

180K)

T21

T23

T19

T20

T18

FLOAT

SWITCH

COVER

OVERTEMPERATURE

CUT OUT

(GD 120 ONLY)

ALARM

NEON

CHASSIS EARTH BRKT

DISPLAY PCB

12V UNREG

POWER SUPPLY PCB

from IC 1

PROBE

5V REGULATED

PL5/2

Fig 1 Power Supply Circuit Diagram GD100/100L/120/120L

NOTE:
RESISTOR VALUES SHOWN;
230V version
(110V version)

GD100/GD120

Page 19

Summary of Contents for OPTIMA RANGE GD100

Page 1: ...IN THE LABORATORY SERVICE MANUAL for the OPTIMA RANGE GENERAL PURPOSE TEMPERATURE CONTROLLER GD100 GD120 Part No 17592 Issue 1 July 2002 ...

Page 2: ... 12 6 2 Removal of Cover 12 6 3 Removal of front panel assembly 12 6 4 Removal of Display PCB 12 6 5 Removal of PSU PCB 12 6 6 Removal of Heater 12 6 7 Removal of Probe 12 6 8 Removal of Float Switch 6 9 Removal of Float and Float Shaft 13 6 10 Removal of GD120 Motor 13 6 11 Removal of GD100 Motor 13 6 12 Replacement of Over temperature Cut out GD120 only 7 Setting Up and Testing 14 7 1 Test Equip...

Page 3: ...fety Tests 8 1 Earth Bonding Test 16 8 2 Insulation Resistance Test 16 9 Final Inspection 10 List of Spare Parts 11 Drawings 12 Probe Resistance Values 18 16 17 18 16 GD100 GD120 Part No 17592 Issue 1 July 2002 Page 3 ...

Page 4: ...help with repairs After unpacking retain packing case and packing for transportation 1 3 Cautions and Warnings The safety statements in this service manual comply with the requirements of the HEALTH AND SAFETY AT WORK ACT 1974 In particular Caution and Warning statements are given in the form shown CAUTION Use to indicate a correct method or procedure to be followed to avoid damage to equipment an...

Page 5: ...e fuses located in the drawer below the mains input socket and may be removed using a small screwdriver to gain access to the fuses The correct fuses are 1 25inch x 0 25inch ceramic rated at 10 amps 110 115V Version This version of the unit has its power supply cable permanently fixed to the rear of the unit The fuses are located in two panel mounted fuse holders turning the cap with a screwdriver...

Page 6: ... Liquid level float switch Over temperature cut out Self resetting thermal cut out in motor Fuses ceramic 240V version 115V version GD120 0 120 C ambient 5 99 C LED 1 5Kw 1 4Kw Yes 2 9Kg 4 3Kg 115 145 315 w d h Yes Yes Yes 2 X 10 amp 2 X 20 amp 2 Specification For use in the following laboratory conditions Power supply Voltage options 220 240V a c 50 60Hz 110 120V a c 50 60Hz Room temperature 10 C...

Page 7: ...lastomer front panel which also has the operating buttons 4 Description of Operation 4 1 AC Power Distribution and Component Interconnections There are two printed circuits in the unit the which contains the power supplies for both boards and the components for driving the heater triac IC3 The other board is the which is screwed to the front panel and contains the processor and display and is wher...

Page 8: ...cessor via the F function and S set buttons on the front panel IC10 is a programmable memory which stores the parameters calculated for the unit calibration 4 5 Temperature Control With reference to the POWER SUPPLY CIRCUIT DIAGRAM it can be seen that the analogue signal from IC1 on the display board is fed to opto isolator IC1 through PL 7 and then to pin 4 of IC2 via potential divider R7 and R2 ...

Page 9: ...on is not lit If alarm neon is lit then check that there is enough water in the test tank to lift the float to operate the float micro switch If the unit is a GD120 and the alarm neon is still on check that the over temperature cut out is turned fully clockwise and reset button is pressed Check that the stirrer is working If stirrer is not running check that the motor shaft turns freely If it is j...

Page 10: ...t shaft slides up and down freely and operates the micro switch Check that the float has not sprung a leak and filled with water Disconnect unit from mains supply and remove leads from float micro switch With multi meter set to resistance range check that micro switch switches on and off as lever is operated Check the over temperature cut out by disconnecting the unit from mains supply and removin...

Page 11: ...E AND FLASHES WHEN S BUTTON IS PRESSED Ensure button is making good contact with track on pcb Replace IC9 microprocessor SET TEMPERATURE WILL NOT CHANGE WHEN TURNING SET TEMP KNOB Replace encoder on pcb Replace IC9 microprocessor HEATER WILL NOT TURN OFF WHEN LIQUID TEMPERATURE IS REACHED Check triac by unsoldering one end of R6 on Power pcb Triac should turn off If it stays on it must be replaced...

Page 12: ... carefully noting positions of button spring and stop plate see FIG 20 With a small screwdriver gently lift clips holding printed circuit board Panel is now free to be removed See Fig 7 See Fig 8 6 4 Removal of Display PCB Remove front panel above Remove processor IC9 to gain access to pcb clip Unscrew over temperature cut out and remove carefully noting position of button spring and stop plate fo...

Page 13: ... 15 See Fig 16 See Figs 17 18 Unscrew stirring propeller from bottom of pump shaft Remove pump housing which is secured with four screws K Remove the pump impellor which is held by a grub screw L Remove all screws from the base plate which may now be removed by pushing sideways to release the clips at the rear edge Slide the moulding and base plate down the motor shaft far enough to gain access to...

Page 14: ...driver to push down the float check that the motor stops and the alarm neon illuminates d Release the float ensuring that it rises Check that motor starts and alarm neon goes out e GD120 only Turn over temperature cut out screw anti clockwise and ensure that alarm neon illuminates Turn screw fully clockwise and press button make sure alarm neon goes out 7 3 Setting up DAC output If the display boa...

Page 15: ...nit to stabilise for at least 5 minutes b Press F and S simultaneously for 5 seconds The display should show LCAL It may take several attempts to achieve this c Press S d Turn knob so that the average temperature of the display over a period of 15secs equals the temperature on the external thermometer e Press S to accept f Press F g Set temperature to 70 C h Allow the water temperature to reach 70...

Page 16: ... button Connect the live and neutral pins of the power supply plug together Use a 500V insulation resistance tester and measure the insulation resistance between the earth and live neutral pins This should be greater than 10 Mohm 9 Final Inspection a Check that wiring is not trapped or nipped b Check that the over temperature cut out bulb has been fitted correctly to the heater c Check that cut ou...

Page 17: ...I C 25LC080P I C UAA 1016B I C HCNW 135 I C LM 7805 TransistorZVP Diode1N4006 Zener Diode3V3 Encoder Pump Blanking Plate O Ring for use with 16868 User Manual 10 List of Spare Parts GD100 GD120 220 240V 02407 04045 16542 16821 16833 16819 16548 09794 09795 16833 09810 13948 16612 16617 04038 GD100 DISP PCB GD120 DISP PCB GD100 PSU PCB 01542 16656 11324 12238 16673 16675 16677 16869 17054 03985 166...

Page 18: ...gram GD100 and GD120 Wiring Diagram GD100L and GD120L Mechanical Diagrams Temperature ºC Resistance W 0 1000 0 5 1019 5 10 1039 0 15 1058 5 20 1077 9 25 1097 3 30 1116 7 35 1136 1 40 1155 4 45 1174 7 50 1193 9 55 1213 2 60 1232 4 65 1251 6 70 1270 7 75 1289 8 80 1308 9 85 1328 0 90 1347 0 95 1366 0 100 1385 0 12 Probe Resistance Values GD100 GD120 Part No 17592 Issue 1 July 2002 Page 18 ...

Page 19: ...3 PL7 1 PL7 6 PL7 2 PL7 7 PL5 1 FS 1 FS 1 FS 2 MAINS SWITCH IEC MAINS SOCKET 110V UNIT 230V UNIT L N E LIVE smooth wire FS 2 NEUTRAL ribbed wire HEATER HEATER NEON R9 270K 180K T21 T23 T19 T20 T18 T4 T3 T2 T7 T3 M FLOAT SWITCH COVER COVER OVERTEMPERATURE CUT OUT GD 120 ONLY ALARM NEON CHASSIS EARTH BRKT DISPLAY PCB 12V UNREG POWER SUPPLY PCB from IC 1 PROBE 5V REGULATED 0V PL5 2 Fig 1 Power Supply...

Page 20: ...6 1 CLK 9 7 R5 2K2 TR1 ZVP2110AD R1 2K2 6 4 3 2 1 18 15 19 12 16 34 35 26 21 21 3 SCK S1 S0 7 6 2 5 1 4 ENCODER 22 23 23 20 1 22 19 8 8 8 8 VR1 20K LED4 x100 5V LED3 x10 LED2 x1 LED1 x0 1 40 7 25 7 6 2 4 5 3 1 3 1 2 7 8 6 5 C36 10µ 0V PL7 1 PL7 3 PL7 4 PL7 5 C11 0µ01 C15 0µ01 RP3f 10K RP3e 10K 5V 8 VCC WP CS HOLD 0V 5V 8 PL7 7 0V IN IC1 OPTO ISOLATOR PL7 2 PL7 6 12V UNREG IN 0V 6 0V 27 R3 10K 5V 1...

Page 21: ... T6 T7 T7 T8 T8 T9 T9 T10 T10 T15 T15 T18 T18 T23 T23 T24 T24 RL1 RL1 RL3 RL3 T25 T25 D3 D3 C7 C7 R9 R9 R10 R10 C9 C9 R11 R11 PL6 PL6 C1 C1 C8 C8 C10 C10 DP307 PSU DP307 PSU R12 R12 IC4 IC4 PL7 PL7 R13 R13 VR1 VR1 ISSUE 8 ISSUE 8 THESE COMPONENTS NOT FITTED Fig 3 Component Layout for Power Supply PCB GD100 GD120 Part No 17592 Issue 1 July 2002 Page 21 ...

Page 22: ...C15 C16 C16 C17 C17 C18 C18 C19 C19 C20 C20 C21 C21 C22 C22 C23 C23 C24 C24 C25 C25 C26 C26 C28 C28 C29 C29 C30 C30 C31 C31 C32 C32 C34 C34 C35 C35 C36 C36 L1 L1 L2 L2 PL1 PL1 PL3 PL3 PL4 PL4 PL5 PL5 PL7 PL7 RP2 RP2 RP3 RP3 RP4 RP4 WD1 WD1 XT1 XT1 ENC1 ENC1 IC13 IC13 IC12 IC12 C27 C27 C37 C37 DP307 PROCESSOR PCB DP307 PROCESSOR PCB 16551 iss 10 16551 iss 10 1 1 Fig 4 Component Layout for Display P...

Page 23: ...A 12 A 10 A 9 A 8 A 6 A 5 A 4 A 3 A 2 A 1 VIEW LOOKING AT MICRO SWITCH SHOWING POSITION OF TERMINALS VIEW LOOKING AT POWER SWITCH FROM INSIDE OF UNIT SHOWING POSITION OF TERMINALS T7 A 12 A 1 A 8 PL7 16902 VIEW LOOKING AT IEC SOCKET FROM INSIDE OF UNIT SHOWING POSITION OF TERMINALS WIRE NUMBER HARNESS WIRE IDENTIFICATION PART NUMBER HARNESS 2 1522 A A 1 BN WIRE COLOUR BN BROWN BL BLUE WH WHITE G Y...

Page 24: ...N BN BN BN BN BL BL WH G Y G Y T2 T3 T4 T20 T18 T19 T23 T21 T22 T15 T24 T25 T6 PL6 PL6 PL7 PL7 T9 T10 T8 PL5 PL4 PL3 ALARM HEATER MOTOR HEATER FLOAT SWITCH OVERTEMPERATURE CUTOUT MICROSWITCH BRACKET EARTH BRACKET COVER CHASSIS CHASSIS NEUTRAL ON CORDSET RIBBED WIRE A 8 POWER SWITCH FS1 FS2 LINE SMOOTH WIRE NEUTRAL RIBBED WIRE EARTH POWER SUPPLY P C B DISPLAY P C B INTERNAL PROBE A 1 A 2 A 8 A 9 FI...

Page 25: ...B x4 A C Fig 7 Fig 8 Fig 9 GD100 GD120 Part No 17592 Issue 1 July 2002 Page 25 ...

Page 26: ...D E x2 F PCB Clip D Fig 10 Fig 11 Fig 12 GD100 GD120 Part No 17592 Issue 1 July 2002 Page 26 ...

Page 27: ...N P H Fig 13 Fig 14 Fig 15 Heater wires Cutout Bulb G GD100 GD120 Part No 17592 Issue 1 July 2002 Page 27 ...

Page 28: ...Part No 17592 Issue 1 July 2002 Fig 16 J K x4 L Fig 17 M M M Fig 18 Page 28 ...

Page 29: ...N x2 N x2 Fig 19 Fig 20 GD100 GD120 Part No 17592 Issue 1 July 2002 Page 29 Fixing screws OverTemperature Cutout Cutout plate Spring ...

Page 30: ......

Page 31: ......

Page 32: ...Grant Instruments Cambridge Ltd Shepreth Cambridgeshire SG8 6GB England Tel 44 0 1763 260811 www grant co uk Fax 44 0 1763 262410 Part No 17592 Issue 1 July 2002 ...

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