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4700 Refrigerated Sampler Service Guide

Section 2 Sample Delivery System

2-21

Figure 2-27 Install heater under pump

5. Secure the heater in place with the two #14



self-tap-

ping

screws. Tighten the screws until fully seated.

6. Refer to Figure 2-28 and secure the AC line cord just inside

the notch in the cover, with the clip and the #8



self-tapping

screw.

Figure 2-28 Install line cord clip

3 mm

(

in)

30 mm

(1.2 in)

Summary of Contents for 4700

Page 2: ......

Page 3: ...th wet hands or when your feet are in contact with water WARNING AC electrical power must meet the applicable electrical code requirements for your installation and must be provided with an earth ground connection If necessary consult with a certified electrician to ensure that AC power is provided in accordance with the local electrical code The AC power cord of this device is equipped with a thr...

Page 4: ...tion provided by the instrument may be impaired this will increase your risk of injury Additional safety information can be found in Appendix B Hazard Severity Levels This manual applies Hazard Severity Levels to the safety alerts These three levels are described in the sample alerts below CAUTION Cautions identify a potential hazard which if not avoided may result in minor or moderate injury This...

Page 5: ...ion Risque de pincement Ces symboles vous avertit que les mains ou les doigts seront blessés sérieusement si vous les mettez entre les éléments en mouvement du mécanisme près de ces symboles Warnungen und Vorsichtshinweise Das Ausrufezeichen in Dreieck ist ein Warnzeichen das Sie darauf aufmerksam macht daß wichtige Anleitungen zu diesem Handbuch gehören Der gepfeilte Blitz im Dreieck ist ein Warn...

Page 6: ...Isco 4700 Refrigerated Sampler Service Guide Safety iv ...

Page 7: ... and Replacement 1 14 1 7 1 Module Reassembly 1 14 1 8 Accessing the Rear Components 1 15 1 9 Closing the Rear Compartment 1 16 Section 2 Sample Delivery System 2 1 Pump 2 1 2 2 Pump Module Replacement 2 2 2 3 Pump Disassembly and Parts Replacement 2 4 2 3 1 Pump Part Numbers 2 4 2 3 2 Thumb Screw 2 6 2 3 3 Pump Housing Cover and Band 2 6 2 3 4 Optical Disk Sensor 2 8 2 3 5 Recent Changes to the P...

Page 8: ... 3 I O Ports U11 14 4 2 4 1 4 Power Supplies U12 13 15 VR1 P11 4 2 4 1 5 Serial Port U32 4 3 4 1 6 Flow Meter Interface U6 17 P2 4 3 4 1 7 Liquid Detector U3 10 P7 4 3 4 1 8 Temperature Inputs U16 P5 4 3 4 1 9 Microprocessor Supervision U23 4 3 4 1 10 Distributor Motor Drive U1 P1 Rotation Sensor P4 U9 4 4 4 1 11 LCD U29 31 33 34 35 36 J1 4 4 4 1 12 Pump Drive U17 18 19 20 21 22 Q1 8 P9 P10 P8 4 4...

Page 9: ...p Information 5 13 5 2 8 Duty Cycle 5 13 5 2 9 Language 5 13 5 2 10 Enabling SPAs 5 13 5 2 11 Nonstandard Bottle Setup 5 13 Appendix A Electrical Diagrams Appendix B Replacement Parts List B 1 Sampler Refrigerator Replacement Parts B 2 B 2 Bottle Configuration Replacement Parts B 32 List of Figures 1 1 16 pin rear connector 1 4 1 2 4700 Pump 1 6 1 3 Rollers A and guides B on the pump rotor 1 7 1 4...

Page 10: ... 27 2 35 Improperly positioned timing belt 2 28 2 36 Installing the cover plate 2 28 2 37 Timing belt alignment 2 29 2 38 Installing the optical sensor 2 29 3 1 Location of temperature sensors reverse view of module 3 3 3 2 Connector wiring of the temperature sensors 3 3 3 3 Control panel module removal 3 4 3 4 Temperature sensor cable wiring connector 3 4 3 5 Temperature sensor wiring entry at re...

Page 11: ...230V line cord plug adaptor 4 21 4 15 Remove power supply cover 4 23 4 16 Line cord connections 4 24 4 17 Removing the line cord from the mounting plate 4 24 5 1 Distributor arm A discharge tube B and stop C 5 4 5 2 Distributor arm positioning discharge tube removed 5 5 5 3 Manual check of compartment heater operation 5 10 A 1 Location of serial tag A 1 A 2 4700 wiring diagram 120V A 3 A 3 4700 wi...

Page 12: ...4700 Refrigerated Sampler Service Guide Table of Contents x ...

Page 13: ...rou bleshooting servicing and replacing the temperature sensors and refrigeration system and its components Section 4 CPU and Power Supply contains a detailed description of the CPU board and test points CPU board tests and instructions for removal replacement of the control panel power supply and line cord Section 5 Electrical Troubleshooting and Diagnostics contains diagnostic testing and troubl...

Page 14: ...g current 1 4 amperes Stalled compressor current 21 3 amperes 230 VAC 10 50 Hz Sampler Running current 0 82 amperes Stalled current 17 amperes Installation Category II Pollution Degree 3 Maximum Altitudea 2 000 meters Humidity 0 to 100 Operational Temperature 29 to 49 C 20 to 120 F Pump Intake Suction Tubing Length 1 to 30 m 3 to 99 feet Material Vinyl or FEP lined polyethylene Suction Line Inside...

Page 15: ...Frequency 1 minute to 99 hours 59 minutes in 1 minute increments 1 to 9 999 flow pulses Sampling Modes Constant Time Constant Volume Variable Time Constant Volume Constant Time Variable Volume Variable time and variable volume modes are controlled by an external flow meter signal Programmable Sample Volumes 10 to 9 990 ml in 1 ml increments Sample Retries If no sample is detected up to 3 attempts ...

Page 16: ...ctions Cable 69 4704 042 is recommended See section 4 3 2 5 Event Mark Output 3 second 12 VDC pulse at beginning of sample collection 6 Enable Pinb Input Ground this input short to pin 2 to disable sampler operation Leave this input open floating to collect samples 7 12 VDC Output 12 5 VDC 1 ampere maximum Power for external devices 8 Alarm 1c Output Alarm Off 0 VDC Alarm On 5 VDC 9 Alarm 2c Outpu...

Page 17: ...Remove power from the sampler before opening the pump housing 2 Refer to Figure 1 2 Release the latch H securing the metal pump housing band K 3 Swing the pump housing band away from the pump hous ing 4 Inspect the following a Pump tube Look for excessive wear caused by the pump rollers and for cracks along the sides of the tube Cracks might not be apparent unless you flex or squeeze the tubing If...

Page 18: ... cool working components If the sampler is programmed to pump in the absence of liquid in excess of 5 minutes excessive heat buildup may damage the paddles rollers and housing Ensure that the liquid inlet is completely immersed A Pump Tube F Liquid Detector Cover B Bulkhead Fitting G Latch C Tubing Coupler H Knob D Alignment Notches I Pump Housing E Alignment Collars J Pump Housing Band A B C G H ...

Page 19: ...co vendors and tubes designed for other types of samplers should not be used Incorrect pump tubing may result in poor pump performance or even cause parts to fail Also note that the discharge tube is not the same as the pump tube Refer to Figure 1 2 and the following steps to replace the pump tube 1 Disconnect the power to the sampler to ensure that it will not attempt to operate the pump WARNING ...

Page 20: ...ly with the large knob 9 Close the pump housing band and secure it with the latch 10 Reset the pump tube counter See the Resetting the Pump Tube Alarm example 11 Take a dry grab sample section 4 4 to test the new tube 12 Reconnect the suction line Pump Tube Life Several factors shorten the pump tube life including Incorrect installation Abrasive materials suspended in sample liquid Frequent line r...

Page 21: ...n water and pump it through the delivery system to rinse it If these items are severely contaminated replace them Example Resetting the Pump Tube Alarm 1 From the Main Menu screen select CONFIGURE 2 Step through the Configure options until you see the TUBING LIFE display Press Enter 3 The sampler briefly displays the current pump count information Line one lists the pump counts since the last rese...

Page 22: ...ts may extend the usable life of the sampler When necessary clean the exterior and interior of the sampler with warm soapy water and brush then rinse with water Be sure to use a detergent that is compatible with low density polyethylene and polystyrene Avoid using strong solvents and acids A Strainer 316 stainless steel polypropylene or CPVC E Bulkhead Fitting 316 stain less steel B Suction Line v...

Page 23: ...pped file contains two files the 4700 software bin file and a pdf file documenting the history of all 4700 soft ware updates to the present Extract these two files 3 With the 4700 turned on connect it to your computer The optional 3 8 m 12 5 ft RS 232 serial communication cable 69 4704 042 connects the DB9 pin serial port of a computer to the serial port interrogator port on the sam pler Connectio...

Page 24: ...set To reset the software 1 Disconnect power to the sampler 2 Hold down the Stop and Enter buttons together and recon nect the power 1 5 3 System IDs Select this option to view the system IDs This function reports the unique ID for the sampler and its hardware and software versions These IDs are factory set 1 Select the SYSTEM IDs option and press Enter 2 The first line lists the model number The ...

Page 25: ...rator components Always service modules in a dry cor rosion free environment CAUTION Modules contain circuit boards and sensitive electronic devices which can be damaged by a discharge of static electricity Avoid touching the internal components Always handle the module by the edges or exterior surfaces CAUTION Electrical connectors and wires can be damaged if improperly handled Electrical connect...

Page 26: ...rs To replace a module 1 Ensure that the gasket seal is in place The gasket surface must be smooth clean and free of nicks cracks etc If any imperfections are visible replace the seal 2 Reconnect the wiring connectors using care to correctly pair the connectors and to correctly align the keys and pins 3 Ensuring that no wires are caught between the module and mounting surface align the module over...

Page 27: ...n module Only trained service personnel may access these areas 2 Remove the cover brace back cover and insulation panel Figure 1 7 3 Remove the module mounting screws Note that the refrigeration module has an adhesive strip just above the rear coils The bottom center screw may be slightly hidden by this strip 4 Carefully turn the module out and to the left to expose the wiring connectors Figure 1 ...

Page 28: ...ps and Permagum are still in place before reassembly CAUTION The adhesive strips and Permagum are required to prevent air flow between the condenser coil and the evaporator plate Without this protection water condensation on the coil will cause ice build up resulting in poor refrigerator performance and inability to shut off Note Two thick black cables connect the power supply with the AC and comp...

Page 29: ...ved Adhesive strips Permagum sealant power cables Figure 1 9 Rear view of refrigeration module Adhesive strip Permagum sealant Replace the refrigeration module insulation rear panel and cover brace reversing the steps in Section 1 8 Power supply cables Adhesive strips Permagum sealant Permagum sealant Adhesive strip Center screw ...

Page 30: ...4700 Refrigerated Sampler Service Guide Section 1 Introduction and General Guidelines 1 18 ...

Page 31: ...maintenance refer to Sections 1 4 1 through 1 4 5 For a description of detector and pump drive circuitry refer to Sections 4 1 7 and 4 1 12 For com ponent part numbers refer to Table 2 1 on page 2 4 Functional testing and diags For functional CPU board testing through Hyper Terminal see Section 4 3 3 Functional Tests The tests are listed by category in Table 4 2 Refer to Section 5 1 5 for standard...

Page 32: ... 2 remove the pump tube 2 Beginning with the three bottom screws remove the six mounting screws see Figure 2 2 holding the module in place to avoid pull or strain on the wires 3 Pull the module away from the refrigerator body and dis connect the four wiring connectors 4 Clean the pump module mounting surface on the refrigera tor body This will help ensure that the gasket on the new module will sea...

Page 33: ...d tighten and torque to 16 to 18 in lbs CAUTION Ensure that all wires are tucked into the pump module com partment and not caught between the gasket and mounting surface 9 Replace the pump tube 10 Perform a pump diagnostic test Section 5 1 5 Figure 2 2 Pump module replacement Figure 2 3 Reinstalling the pump module Wiring connectors Detector knob Insert top row of screws first Ensure that wires ar...

Page 34: ... details the replacement steps for pump components and describes recent changes to the pump 2 3 1 Pump Part Numbers Table 2 1 contains a list of pump components with part numbers Test port Do not remove screw Table 2 1 Pump Parts List Part Number Thumb screw 60 4704 055 O ring 202 5000 07 Gasket 60 3113 029 Pump shaft assembly 60 4708 002 Idler gear old 60 4708 003 Idler gear new 60 4708 017 Motor...

Page 35: ... 5 Optical sensor wiring assembly 69 4704 025 Hold down kit for detector barrier 68 4700 037 Pump base with detector 68 4704 039 Pump cover installation kit 68 4700 101 Pump heater kit 120 VAC 68 4700 104 Pump heater kit 230 VAC 68 4700 105 Table 2 1 Pump Parts List Continued ...

Page 36: ...and by opening the latch Remove the four screws holding the cover in place CAUTION The screw nearest the edge Figure 2 6 must be reinstalled with great care as it is possible to strip the plastic threads This screw should always be the last to install Figure 2 6 Opening the pump housing cover and latch CAUTION When reinstalling all self tapping screws avoid destroying the plastic threads First sea...

Page 37: ...e bushing into the bottom side of the cover until it is flush against the cover Figure 2 7 Top cover bushing Pump band Once the latch is open and the top cover removed the metal pump band simply lifts away from the hinge pin The magnet housed within the band is not removable Figure 2 8 Pump band removal Latch To replace the pump band latch first unlatch it and open the pump band The latch is attac...

Page 38: ...l disk grasp the pump rotor to hold the shaft in place and remove the mounting nut Carefully tilt and slide the disk away from the sensor If the optical sensor must be removed remove the two Allen screws holding it in place 1 4 lock nuts in older models Figure 2 10 Optical disk and sensor removal CAUTION Do not allow the disk to scrape against the optical sensor dur ing removal replacement The opt...

Page 39: ...nd the sampler serial numbers corre sponding to the changes CAUTION Although the old pump will work with the new power supply the new pump will NOT work with the old power supply 69 4704 010 Do not install the new pump without ensuring that the sampler also has the new power supply See Section 4 5 1 for additional information about the power supply Power Supply 69 4704 010 Old no longer available ...

Page 40: ...hamber Corre spondingly the idler bushing is located in the middle right hole in the plate Figure 2 11 Old and new mounting plate idler gear on opposite side The new pump module has a different idler gear with more teeth The old and new gears are visibly different from one another Figure 2 12 Figure 2 12 Old and new idler gears Idler bushing old position Idler bushing current position Motor gear O...

Page 41: ...unt the motor to the plate Do not remove the motor gear from the motor shaft Replace as an assembly The brass idler gear bushing engages with the idler gear shaft When seating the idler gear first lubricate its shaft with grease The black plastic bushing also known as the thrust bushing normally rests on the shaft of the drive gear acting as a spacer see Figure 2 14 If replacing one or both of the...

Page 42: ... counter clockwise until it falls into its thread groove with a click Then tighten the screw This precaution is not necessary with new unthreaded holes Figure 2 15 Motor plate mounting holes Wiring assembly The motor wiring harness is easily replaceable 1 Disconnect the two wires from the motor terminals Older pump harnesses may have spade connectors that pull off newer pump harnesses are soldered...

Page 43: ...et not sealing when the pump module is attached to the cabinet 2 3 8 Rotor The pump rotor is attached to the gear shaft with a screw on the side with two posts and a nut on the other side Figure 2 17 Always make sure the screw and nut are on the correct sides The rotor has no top or bottom the two posts will always be posi tioned correctly regardless of the rotor s orientation Figure 2 17 Pump rot...

Page 44: ...he opposite corner This prevents the gasket from being unevenly distributed in the groove ensuring the integrity of the seal 3 Press the other corners in followed by the rest of the gas ket Figure 2 18 Proper installation of the gasket Note Installing the gasket without following these steps will result in uneven distribution of the gasket as shown in Figure 2 19 This will result in moisture liqui...

Page 45: ...f it is damaged the entire pump base must be replaced Barrier removal and replacement 1 Remove the four self tapping Phillips screws attaching the hold down panels and pull them off 2 Peel the barrier away from the detector 3 Apply a thin layer of 737 RTV sealant 800 1002 03 to the outer edges of the mounting surface taking care to avoid getting any in the tubing grooves 4 Install the new barrier ...

Page 46: ...iver Electric drill with 1 8 bit Ruler WARNING The pump is extremely powerful and can injure you severely if the sampler activates while you are servicing it Turn the sampler OFF and remove AC power before performing any service work on the sampler 1 Open the pump cover and following the instructions in Section 2 2 remove the pump module 2 With the cover in the closed position align the bottom hin...

Page 47: ...me 5 Realign the open cover over the holes and reference line Secure the cover in place with three 14 self tapping screws included in kit and tighten them until fully seated 6 Holding the cover closed measure 3 16 4 5 mm in from the front face of the latch and draw a reference line on the frame parallel to the edge Figure 2 23 7 Position the latch keeper small metal plate from kit with the flat ed...

Page 48: ...d The latch should now be able to engage with the keeper securing the pump cover in the closed position Figure 2 24Attaching the latch keeper 10 Leaving the cover open reattach the wiring connectors from the pump module 11 Align the module over the mounting holes and secure it with the mounting screws inserting the top three first After all six screws are inserted tighten and torque to 16 to 18 in...

Page 49: ...revents liquid from freezing only inside the pump housing cover In extremely cold climates you must also route the suction line correctly to prevent liquid from freezing in the suction line The suction line must have a continuous slope Do not allow loops or low spots in the line where liquid can remain between samples This general practice applies to all climates to prevent sample cross contaminat...

Page 50: ...ure 2 26Install heat shield inside cover 3 Temporarily close the pump cover to check the heat shield alignment The hole in the shield must fit over the large knob on the pump assembly If the shield hits the knob loosen the four screws and adjust the shield When the alignment is correct tighten the screws 4 Position the heater on the sampler as shown in Figure 2 27 Align the edges of the slot in th...

Page 51: ...nder pump 5 Secure the heater in place with the two 14 2 self tap ping screws Tighten the screws until fully seated 6 Refer to Figure 2 28 and secure the AC line cord just inside the notch in the cover with the clip and the 8 5 8 self tapping screw Figure 2 28 Install line cord clip 3 mm 1 8 in 30 mm 1 2 in ...

Page 52: ...re the collection of each sample This can give the appearance of arm drift or misalignment between samples Alignment check To check for proper distributor alignment above each bottle mouth first remove the discharge tube see Figure 2 29 The tension placed on the distributor arm by the discharge tube can create the illusion of misalignment Enter the bottle number to which the sampler should move th...

Page 53: ...isconnect the two distributor cable connectors P1 and P4 see Figure 4 2 3 Remove the distributor arm and discharge tube a Remove the knurled nut that secures the distributor arm and pull the distributor arm downward to disen gage its positioning key from the notch in the shaft b Pull the discharge tube off of the bulkhead fitting in the top front corner of the refrigerator Figure 2 29 Distributor ...

Page 54: ... the control panel module over the mounting holes and secure it with the mounting screws Torque screws 16 to 18 in lbs 11 Align the key in the distributor arm with the notch in the distributor shaft The arm should seat fully onto the shaft as shown in Figure 2 29 using only slight pressure Reinstall the knurled nut and hand tighten Do not over tighten 12 Install the discharge tube into the arm and...

Page 55: ...disk Figure 2 31 Removal of stepper motor and optical sensor Note The optical sensor is fragile Set it aside so that it does not get broken Inspect the sensor and replace if broken 6 Remove the three large screws holding the cover plate in place Remove the plate to expose the timing belt 7 The timing belt distributor shaft assembly and band gas ket simply lift out of the base Figure 2 32 Distribut...

Page 56: ...ll the gasket taut then press the gasket down into the opposite corner This prevents the gasket from being unevenly distributed in the groove ensuring the integrity of the seal 3 Press the other corners in followed by the rest of the gas ket Figure 2 33 Distributor gasket replacement Note Installing the gasket without following these steps will result in uneven distribution of the gasket as shown ...

Page 57: ...tch in the distributor shaft Replace the four screws 3 Reinstall the distributor shaft in the brass bearing in the base Figure 2 34 Reassembling the distributor shaft 2 9 3 Belt and Motor To replace the belt and motor 1 Place the timing belt around the shaft gear as shown in Figure 2 35 Note When replacing the timing belt ensure that the belt s teeth are evenly engaged with those of the shaft gear...

Page 58: ...the three large self tapping screws Figure 2 36 Installing the cover plate 4 While maintaining the belt tension by pressing the motor away from the distributor shaft slowly turn the large gear until you feel the belt jerk as the teeth fall into alignment Figure 2 37 Turn the large gear at least one full revolution to ensure that all teeth have engaged between the pulley and the belt This eliminate...

Page 59: ...h the two self tapping mounting screws Tighten the screws to 10 14 in lbs Figure 2 38 Installing the optical sensor 2 9 5 Distributor Part Numbers Table 2 2 contains a list of distributor components and part numbers Press turn Press turn Press back mounting screws 2 Table 2 2 Distributor Parts List Band Gasket 60 3113 029 Index Disk 69 4703 018 Motor Pulley Assembly 60 4708 010 Motor Mount Accesso...

Page 60: ...4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2 30 ...

Page 61: ...pen end wrench clear silicone sealant Additional tools and supplies specific to troubleshooting and ser vicing the refrigeration module are listed on page 3 9 3 1 2 Parts Unlike the other modules the refrigeration module is voltage specific Be sure to order the replacement module and or appropriate components for your AC mains power Table 3 1 con tains part numbers for voltage specific components ...

Page 62: ... readings 3 3 1 Refrigeration Temperature Sensors The two refrigeration temperature sensors are part of the tem perature sensor wiring assembly The evaporator temperature sensor is distinguished from the wall mounted sensor by a band of black shrink tubing on the wire just behind the sensor located on the sixth coil of the evapo rator Figure 3 1 Detail A Relay 210 0002 04 Overload 6 8 A 210 0002 0...

Page 63: ...pty slot pin 2 between its two wires on the connector as shown in Figure 3 2 Figure 3 2 Connector wiring of the temperature sensors Removing the cable assembly To remove the temperature sensor wiring assembly begin by opening the rear compartment of the refrigerator as instructed in Section 1 8 observing all safety precautions Then 1 Open the top cover of the sampler 2 Remove the control panel mou...

Page 64: ...the panel back in place CAUTION When disconnecting a cable connector always grasp the con nector itself and not the wires Figure 3 4 Temperature sensor cable wiring connector 5 Slide the unmarked sensor out of its black plastic holder located behind the power supply plate Figure 3 1 Detail B 6 Remove the marked sensor from the evaporator coil and rear wall by cutting the two cable ties holding it ...

Page 65: ... 1 Feed the connector end of the new cable through the threaded opening from the rear of the cabinet 2 Apply a coating of the clear silicone sealant such as Dow Corning 737 RTV to the threads of the cable s bulkhead fitting 3 Screw the bulkhead fitting into the cabinet wall until the threads bottom out Smooth the excess silicon sealant around its base to seal the joint 4 Tighten the black plastic ...

Page 66: ... Restore AC power After 30 minutes perform the refrigera tor temperature diagnostic test see Section 5 1 8 As the refrigerator cycles off and on the reported temperature may read above or below the set temperature However the average reported value should be the same as the set tem perature Figure 3 7 Air temperature sensor mounting seen from rear with power supply removed You can also validate pr...

Page 67: ...ld there be a need to verify the temperature readings dis played by the control panel it is important to read the temper ature as close as possible to the sensor inside the refrigerator To verify the temperature without a 24 bottle rack or locating base place a thermometer in a container of water in the right rear corner of the refrigerator The thermometer should sit in front of the return air ope...

Page 68: ...frigeration module WARNING Risk of injury or equipment damage Familiarize yourself with the general instructions on pages 1 14 and 1 13 All inspection and servicing procedures require opening the rear of the refrigerator Refer to Section 1 8 for removal of the refrig eration module from the cabinet and to Section 1 9 for closing the rear compartment 3 4 1 Inspection Troubleshooting and Servicing T...

Page 69: ...re gauges on both service ports Figure 3 11 Figure 3 11 Refrigeration service ports 2 Reconnect line power and allow the refrigerator to run observing the pressure gauges Pressure on the high port should be around 150 psi pressure on the low port should be around 10 psi Copper Tubing Tubing must be cleaned and capped copper refrigeration grade DO NOT use general pur pose tubing Tubing sizes 250 O ...

Page 70: ...ice see Figure 3 15 5 Inspect as described in Table 3 2 and the paragraphs that follow 6 When you are finished checking the line pressure remove AC power from the sampler 7 Crimp the tubing shut behind the saddle tap Remove the saddle tap cut off the tubing end and braze with silver sol der to seal it 8 Coat all brazed areas and exposed metal with lacquer paint and cover with heat shrink tubing CA...

Page 71: ...ng Table 3 2 Refrigeration System Troubleshooting Symptom Cause Action Compressor tries to start then stops has excessive current draw Plugged orifice Replace refrigeration module recommended Compressor failure Compressor runs hot trips thermal breaker Refrigerant leak Outer coil does not heat up while unit is running Compressor does not start at all Relay or capacitor failure Replace component se...

Page 72: ...ich liquid refrigerant changes temperature and pressure before entering the evaporator coil is a very delicate device and is easily clogged It is therefore critical to prevent anything other than refrigerant from entering the system such as solder flux particles water or oxidized copper If the orifice becomes clogged or otherwise damaged replacement of the refrigeration module is recommended due t...

Page 73: ...arrows 3 4 2 Refrigerant On site charging must be performed by licensed service per sonnel only Consult your local laws regarding refrigeration repair WARNING Do not run the compressor during evacuation leak testing or charging 1 Through the low pressure service port evacuate the sys tem to 150 microns or less Dryer Orifice Relay Overload 120V box shown ...

Page 74: ... CAUTION The correct amount of refrigerant is critical to proper operation of the 4700 4 When charging is complete crimp the high pressure ser vice port near the joint and the extension close to the tee see Figure 3 16 A 5 Braze the ends of the service port tubes with silver solder to seal CAUTION All exposed copper tubing MUST be coated with acrylic paint and then covered with shrink tubing to pr...

Page 75: ...erated Sampler Service Guide Section 3 Refrigeration System 3 15 Figure 3 16 Refrigeration charging A B Service Port low pressure Service Port high pressure Shrink Tubing Wrap suction line in cork insulating tape ...

Page 76: ...run when powered it will need to be replaced To verify motor failure disconnect the fan from the compressor and measure the resistance across its two connectors Normal resistance is between 50 and 150 ohms If the motor has burned out the resistance will be very high open Tools Multimeter 5 16 nut driver 2 Phillips screwdriver Removal replacement 1 Pull the plastic terminal cover away from the comp...

Page 77: ... hold down tab to free the harness Figure 3 18 Condenser fan connections 3 Remove the three lock nuts holding the fan assembly in place Remove the fan assembly and vibration cushion Figure 3 19 Removal replacement of condenser fan 4 Place the new vibration cushion and fan assembly on the floor of the refrigeration module aligning the holes in the base over the threaded mounting studs and secure wi...

Page 78: ...priate components for your AC mains power Table 3 1 on page 3 1 contains part numbers for the refrigeration system and its components For a complete listing of replacement parts refer to Appendix B CAUTION Replacement of individual components may compromise the closed refrigerant system and the protective coatings Removal 1 Remove the power cord that runs through the refrigeration assembly Refer t...

Page 79: ...d brown wires from the side of the compres sor Remove the nut holding the green and yellow ground wire on the module chassis These connections are from the line cord routed to the power supply module mounted on the back of the refrigerator cabinet as shown in Figure 1 8 For 100V 120V systems refer to Figure 3 22 For 230V systems refer to Figure 3 23 Figure 3 22 Electrical connections on 100V 120V ...

Page 80: ...s 4 The evaporator sensor is mounted on the sixth coil up on the evaporator Cut the ties holding the evaporator sensor in place and move it out of the frame Figure 3 24Removing evaporator temp sensor 5 Slide the refrigeration module out of the way and move the replacement module into its place Grn Y Br Bu Ribbed Smooth Y Y Bu Bk ...

Page 81: ...y Attach the 230V plug adapter to the end of the power cord Slide the piece of plastic heat shrink tubing over the plugs Then apply a heat source of at least 80 C 176 F to shrink the tubing 5 Move the refrigeration module up to the rear of the refrigera tor and replace the drain tube in the drip pan on the module Figure 3 25Drain tube and drip pan 6 When reinstalling the refrigeration module use c...

Page 82: ...than 38 400 8 data bits no parity 1 stop bit No flow control Auto Detect or VT100 terminal emulation 2 Using your communications software connect to the sam pler Repeatedly type Shift using the computer keyboard until the sampler returns its banner string The banner string lists the model number and unique ID of the sampler A prompt will appear on the screen when it is ready to accept commands 3 A...

Page 83: ... processor used is an Atmel AT91M55800A This processor uses an ARM 7 core Various peripherals are built into the pro cessor Features include 10 bit analog to digital a to d converter 8 to 1 multiplexer which allows 8 external analog inputs to be converted one at a time clock circuitry that allows the processor to run at different speeds an internal real time clock that can run on battery two cryst...

Page 84: ...emory It is static RAM and contains 512 K bytes It is backed up by an on board lithium battery 4 1 3 I O Ports U11 14 These are I O expander chips that communicate serially with the CPU over the SPI bus U14 provides 6 outputs that are column drivers for the keypad which is arranged in a 4 by 6 matrix The 4 row signals come back directly to the CPU The keypad is not continuously scanned Normally th...

Page 85: ...s in on P7 Op amp U3 acts as a high impedance load for the detector and buffers the signal delivered to the discrete multi stage RC filter This filter removes the higher frequency compo nents of the signal U10A is a buffer after the filter U10B and the diode on its output rectify the AC signal to a positive DC signal that goes to an a to d input on the CPU 4 1 8 Temperature Inputs U16 P5 U16 measu...

Page 86: ...er is supplied to the display from linear 5V regulator VR1 4 1 12 Pump Drive U17 18 19 20 21 22 Q1 8 P9 P10 P8 The pump motor connects to P10 and the interlock switch in the pump connects to P9 If the pump band is in place and latched the magnet in the band activates the reed switch in the pump housing and closes the circuit for the interlock There are redundant interlock circuits operating from t...

Page 87: ...g on the signal input to them The signals go through current limiting PTCs R14 17 and protection circuits 4 1 15 Analog Input U7 8 17 30 P3 P3 also has the analog input 4 20 mA which can come from a flow meter and provide flow data for flow proportional sampling This input is electrically isolated from the other circuitry on the CPU The current coming in flows through zener diode CR11 and the 10 o...

Page 88: ...put on the processor With liquid present this value should be above 0 75V TP5 3 3V voltage 2 9 to 3 3 volts TP6 MCKO Master Clock Output This out put is enabled when in the CPU board test mode TEST command through the serial port See Section 4 3 8 MHz signal 125 nsec period TP7 TP8 TP9 VB power to RAM About 2 7V on battery 3 3V on AC power 2 5V minimum TP10 Battery current minus Should be less tha...

Page 89: ... on the screen when it is ready to accept commands From this menu you can access time date read write and functional tests 4 3 1 TIME DATE Read Write TIME_DATE CR This command will return the current time and date set in the real time clock chip in the format of HH MM SS DD MM YY TIME_DATE HH MM SS DD MM YY CR Use this command to adjust the time and date in the real time clock chip Note that the f...

Page 90: ... 2 and A 4 in Appendix A Returns the number of counts for this current then OK to indicate completion The calibrated value will be saved in flash memory when you enter the save command T99 at the end of the test sequence Calibrate analog input at 9mA T09 Apply 9mA to pins 8 and 9 of connector P3 before entering this command Returns the number of counts for this current then OK to indicate completi...

Page 91: ...de On off ratio should be between 0 8 and 1 25 If the optical sensor sees motion the test returns On Off ratio and then OK If not the test returns NOT_OK Test pump drive reverse T27 Optical sensor connections P8 1 power to LED P8 2 power to LED P8 3 3 3V to sensor P8 4 signal from sensor Connect either the actual motor or a simulator at P10 1 and P10 2 Activate the pump drive output in forward mod...

Page 92: ... this data is stored at one minute intervals Returns duty cycle as a percent of ON time for the compressor over the last 4 hours Returns OK to indicate completion Power Display input voltage T35 This test measures and returns the nominal 12V input voltage to the board Returns OK to indicate completion Additional input power testing Power Fail alert measured at TP12 Reduce power input at R34 Goes l...

Page 93: ...at Returns OK on a new line after the serial number line when done Turn off backlight T39 Turns off the backlight for the LCD module Returns OK to indicate completion Turn on backlight T40 Turns on the backlight for the LCD module Returns OK to indicate completion Turn on CPU heater T41 This test applies full power 100 to the heater resistor on the CPU board This will last for 10 seconds and then ...

Page 94: ...Installation Clean the control panel module s mounting surface on the face of the refrigerated compartment This will help ensure that the gasket on the new module will seal the enclosure Ensure that the gasket seal is in place The gasket surface must be smooth clean and free of nicks or cracks If any imperfections are visible replace the gasket Isco part 60 3113 028 Installation 1 Attach the wirin...

Page 95: ...ternal Device Interface P10 Pump Motor P4 Distributor Sensor P11 Power Controller P5 Temperature Sensors P12 Keypad Ribbon Cable P6 Backup Power not shown P13 Not Used P7 Pump Liquid Detector P14 Power Refrigerator Yel Blu Red Orn 1 2 3 4 1 3 4 2 Blk Wht Red Grn Grn Blk Blu Red Brn Wht 1 2 4 5 6 7 Yel Yel 1 3 Green Wht Yellow Wht Violet Wht Black Wht Blue Wht Red Wht Orange Wht Brown Wht 1 2 3 6 7...

Page 96: ...be modified to have this capability Note This provides backup power to the sampler controller only not to the refrigerator To enable power backup connect the module 60 5314 696 to the 16 pin connector on the back of the sampler Connect the Isco power supply to the 2 pin amphenol connector on the module The module duplicates the 16 pin connector to allow connection to other devices Figure 4 3 4700 ...

Page 97: ...e new power supply the new pump will NOT work with the old power supply 69 4704 010 Do not install the new pump without ensuring that the sampler also has the new power supply The old and new power supplies and pumps can be distinguished from each other by their appearance See Figure 4 4 for a com parison of the old and new power supplies For additional infor mation about the updated pump assembly...

Page 98: ...oved 4 5 2 Fuse The new power supply has a fast blow 4A 250V 5mm x 20mm glass fuse to protect the sampler controller This replaceable fuse is located on the converter board behind the white AC connector you may need to disconnect this connector to access the fuse Figure 4 5 Fast blow fuse on the new power supply Old New Fast blow fuse ...

Page 99: ... areas WARNING Risk of injury or equipment damage Familiarize yourself with the general instructions on pages 1 14 and 1 13 before proceeding Tools 1 open end wrench 1 and 2 Phillips screwdrivers heat gun RTV sealant 1 Remove the power cord that runs through the refrigeration assembly Refer to Figure 4 7 a 230V 50 Hz Systems Only Remove the AC Plug adapter from the end of the power cord by first c...

Page 100: ...ire connections on the side of the com pressor and the green and yellow ground wire from the module chassis These three wires come from the power supply For 100V 120V systems refer to Figure 4 8 For 230V systems refer to Figure 4 9 Figure 4 8 Electrical connections on 100V 120V compressors Bushing Bu Br Grn Y R Or Ribbed Smooth ...

Page 101: ...11 and P14 Figure 4 2 These two harnesses come from the black line cord routed through the black cord grip fitting above the upper right corner of the fan between the top and rear compartments of the 4700 Figure 4 10 Figure 4 10CPU CBA cable routing in refrigerator rear wall 4 Unscrew the black cord grip fitting from the bulkhead in the refrigerator s rear wall above the upper right corner of the ...

Page 102: ...cable and bulkhead connector 6 From the front interior of the refrigerator remove the two Phillips screws holding the fan in place and remove the fan s power cable by disconnecting the red and black wires Figure 4 12 Fan mounting screws and power cable 7 Remove the two large Phillips screws from the power sup ply back plate and remove the power supply 4700 rear wall CPU CBA connectors Cord grip fi...

Page 103: ...at the green yellow wire is reconnected to this terminal 3 Route the AC power cord through the refrigeration module and secure it in place with the bushing Figure 3 21 a 230V 50 Hz Systems Only Attach the 230V plug adapter to the end of the power cord Slide the piece of plastic heat shrink tubing over the plugs Then apply heat of at least 80 C 176 F to shrink the tubing Figure 4 14 230V line cord ...

Page 104: ...ten the cord grip fitting onto the bulkhead fit ting 8 Close the rear compartment see Section 1 9 Closing the Rear Compartment 4 6 Line Cord Although the line cord comes attached as part of the power supply assembly it is possible to replace the line cord only if it becomes damaged Tools T 15 torx screwdriver 5 16 nut driver 1 open end wrench approximate size may vary slightly 4 6 1 Line Cord Remo...

Page 105: ...cord ground connec tor on the mounting plate Figure 4 16 3 Disconnect the blue wire from W3 on the power board and the brown wire from W4 on the power board Figure 4 16 Note These two connectors may be difficult to remove Never pull the wires You may need to ease them up from the board with a flat screwdriver Use care not to damage the board torx screws ...

Page 106: ...ng the line cord from the mounting plate 4 6 2 Line Cord Replacement 1 Feed the new line cord through the front of the mounting plate and tighten the black plastic nut onto the bulkhead fitting until both are flush against the plate The bulkhead fitting has a rubber ring that seals the box and prevents the fitting from coming loose 2 Attach the ground wire to the mounting plate with the lock nut a...

Page 107: ...its groove Align the cover over the eight mounting holes and reattach it with the self tapping torx screws CAUTION When reinstalling all self tapping screws avoid destroying the plastic threads First seat each screw in its hole and without pressing down rotate the screw counter clockwise until it falls into its thread groove with a click Then tighten the screw 4 Reinstall the power supply followin...

Page 108: ...4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 4 26 ...

Page 109: ...unit will emit a wavering tone for five seconds In a few cases the service technician must determine if the test passed or failed based on a sampler function that must be observed The sampler automatically reverts to the SELECT DIAG menu after displaying the test results or when the test is complete or expired To start the diagnostics from the standby screen 1 Select the CONFIGURE option and press...

Page 110: ...on and press Enter 2 Wait for the sampler to complete the test 3 When finished the sampler displays the test results If the sampler reports ROM FAILED contact your authorized Isco service facility or the Teledyne Isco factory English language only samplers do not include the known value For these samplers the test will report NO CHECKSUM This result does not indicate a pass or fail state only that...

Page 111: ...CT DIAG menu Note Pressing the red Stop button twice consecutively will exit the test regardless of the number of strokes If the display does not report the button name when you press it the keypad could be faulty Contact your authorized Isco service facility or the Teledyne Isco factory 5 1 5 Test Pump The TEST PUMP diagnostic tests the sampler s pump assembly The sampler operates the pump in eac...

Page 112: ...the sampler s dis tributor alignment You specify the bottle position to which the sampler should move the arm You can then verify the correct positioning of the arm Note This test is not applicable for samplers configured for operation with a single 20 liter bottle To run the test 1 Remove the discharge tube from the distributor arm This removes tension from the arm for better visual verifi cation...

Page 113: ... next bottle position Enter a bottle number and press Enter or press the Stop button to exit the test 9 From the standby screen reenter the code 82253 TABLE to exit Calibrate mode It is important to exit Calibrate mode prior to operation to avoid errors during the running of a program If the sampler displays DISTRIBUTOR JAMMED DISTRIBUTOR ERROR SLOT CODE ERROR DISK ERROR or BELT TOO LOOSE verify t...

Page 114: ...hat test plug is correctly inserted Then perform the TEST FLOWMETER PORT diagnostic again from step 1 If the test still fails contact your authorized Isco service facility or the Teledyne Isco factory 5 1 8 Refrig Temperature The REFRIG TEMPERATURE diagnostic displays the temper ature of the refrigerated compartment When this test is started the sampler should display the temperature until you pre...

Page 115: ... Stop or Enter button The normal voltage range is between 12 3 and 12 7 VDC If the voltage is outside of this range the power supply module is suspect Contact your authorized Isco service facility or the Teledyne Isco factory for further troubleshooting assistance 5 1 11 Battery Voltage The Main CPU board has an internal battery that provides back up power for the sampler memory while the system i...

Page 116: ...d press Enter 2 The display shows the voltage at 1 second intervals for 15 seconds You can abort the test by pressing the Enter but ton The voltage reading is normally between 2 4 and 3 1 VDC If the voltage is below 2 4 VDC the internal battery should be replaced Contact your authorized Isco service facility or the Teledyne Isco factory for assistance Note Should there be a loss of AC power and th...

Page 117: ...two fields that will accept entries for room temperature and refrigerator temperature These values are expressed as numbers between 230 and 999 representing temperatures between 40 and 59 9 C as shown in Table 5 1 Line two of the screen shows the current state of the compressor compartment heater and refrigerator temperature Each value appears for 3 seconds in rotation COMPRESSOR ON OFF COMPARTMEN...

Page 118: ...running and you enter a lower temperature in line one to turn it off then enter a higher temperature to turn it back on the compressor will still remain off for 2 minutes Press STOP to exit If no keys are pressed for 10 minutes while in this screen the sampler will exit this mode and go back to the main menu 5 2 2 Compressor Control An additional hidden menu for controlling the compressor is acces...

Page 119: ...0 14 650 25 77 310 9 15 8 660 26 78 8 320 8 17 6 670 27 80 6 330 7 19 4 680 28 82 4 340 6 21 2 690 29 84 2 350 5 23 700 30 86 360 4 24 8 710 31 87 8 370 3 26 6 720 32 89 6 380 2 28 4 730 33 91 4 390 1 30 2 740 34 93 2 400 0 32 750 35 95 410 1 33 8 760 36 96 8 420 2 35 6 770 37 98 6 430 3 37 4 780 38 100 4 440 4 39 2 790 39 102 2 450 5 41 800 40 104 460 6 42 8 810 41 105 8 470 7 44 6 820 42 107 6 4...

Page 120: ... serial port every minute Seven items are reported in the string The first data field reports each minute as a 3 digit time counting from 000 to 999 and then starting over The second field is Temp xx x where xx x is the reading from the refrig erator air temperature sensor in C The third field is Delta xx x where xx x is the rate of temperature change while the com pressor is running The fourth fi...

Page 121: ...This is the same menu that can be accessed through CON FIGURE LANGUAGE English will always be available If other languages are loaded they will also be in the list 5 2 10 Enabling SPAs As of software version 2 0 SPA software modifications can be accessed by entering the code 47009 The access code is not nec essary for SPAs that are free As of this release the only free SPA is 1709 5 2 11 Nonstanda...

Page 122: ...4700 Refrigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics 5 14 ...

Page 123: ... a schematic diagram of the 4700 CPU CBA The schematic shown is for the current version with battery backup capability Note that this manual does not contain all versions of electrical diagrams To access electronic copies of schematics visit http www isco com support schematics asp and enter the serial number for the correct schematic version for your sampler The serial tag is located on the inter...

Page 124: ...4700 Refrigerated Sampler Service Guide Appendix A Electrical Diagrams A 2 ...

Page 125: ...4700 Refrigerated Sampler Electrical Wiring A 3 4700 Refrigerated Sampler Electrical Wiring Figure A 2 4700 wiring diagram 120V ...

Page 126: ...4700 Refrigerated Sampler Electrical Wiring A 4 Figure A 3 4700 wiring diagram 230V ...

Page 127: ...ock 3 3V 3 3V Counter D Gnd 12V Gnd Flow Pulse Interr Out Event Mark Inhibit Interr In VF Out 1 Out 2 Out 3 Out 4 4 20mA In 4 20mA In D Gnd P8 P7 P14 Pump Interlock Interlock Rotation Sensor Liquid Detector Pump Refrigeration Control Sample Temp Comp Heat Fan Ref Heat Refrig Flow Meter Interface Cable Sample Temperature Probe optional 5 Temp Gnd AC Out AC In 12 12 Gnd 12 Gnd Gnd Evaporator Fan Com...

Page 128: ...4700 Refrigerated Sampler Electrical Wiring A 6 Figure A 5 4700 CPU schematic diagram ...

Page 129: ... the call out in the adjacent table to determine the part number for the item Replacement parts can be purchased by contacting Teledyne Isco s Customer Service Department Teledyne Isco Inc Customer Service Department P O Box 82531 Lincoln NE 68501 USA Phone 800 228 4373 402 464 0231 FAX 402 465 3022 E mail IscoInfo teledyne com ...

Page 130: ...4700 Refrigerated Sampler Appendix B Replacement Parts List B 2 B 1 Sampler Refrigerator Replacement Parts ...

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