NÜVE SANAYİ MALZEMELERİ İMALAT VE TİCARET A.Ş.
EC 160 CO2 INCUBATOR SERVICE MANUAL
1984
Z14.K 25 137
Rev. No:01
Rev. Tarihi:12/2013
TABLE OF CONTENTS SECTION 1 - INTRODUCTION ............................................................................................. 4 1.1
PURPOSE OF THE SERVICE MANUAL .................. ......... ................... ................... .................. .................. .................. ......... 4
1.2
GENERAL PURPOSE OF THE UNIT..................... UNIT............ .................. .................. ................... ................... ................... ............ .. 4
SECTION 2 - OPERATING PRINCIPLES ............................................................................. 5 2.1 2.2
GENERAL OVERVIEW ................... ......... ................... .................. ................... ................... .................. ................... ................... ................ ....... 5 EXPLANATIONS OF THE FUNCTIONS ................... .......... ................... ................... .................. .................. .................. ......... 5
2.2.1
Power Supply Values ................... .......... ................... ................... .................. ................... ................... .................. ................... ............ .. 5
2.2.2
Command and Control Unit .................. ......... ................... ................... .................. ................... ................... .................. ............. .... 5
2.2.2.1 2.2.2 .1 Main Main PCB ............................... ................................................ .................................. .................................. .................................. ................... .. 5 2.2.2.2
Programming and Operating Control Panel .................. ......... ................... ................... .................. ........... 5
2.2.3
Heating Unit ................... .......... ................... ................... .................. ................... ................... .................. ................... ................... ................ ....... 6
2.2.4
Humidification Humidification Unit ................... ......... ................... .................. ................... ................... .................. ................... ................... ................ ....... 6
2.2.5
CO2 Gas Unit ............................. .............................................. ................................. .................................. ................................... ................... .. 6
2.2.5.1 IR Sensor ................... .......... ................... ................... .................. ................... ................... .................. ................... ................... ................ ....... 6 SECTION 3 - SERVICING ..................................................................................................... 7 3.1
GENERAL OVERVIEW ................... ......... ................... .................. ................... ................... .................. ................... ................... ................ ....... 7
3.1.1
PERIODIC MAINTENANCE MAINTENANCE ................... ......... ................... .................. ................... ................... .................. ................... ............ .. 7
3.2
GENERAL FAILURES................... .......... .................. ................... ................... ................... ................... .................. .................. .................. ......... 8
3.3
TEMPERATURE TEMPERATURE REGULATION OPERATING FAILURE................... ......... ................... ................... ............ .. 9
3.4
CO2 GAS CONTROL FAILURES ...........................................................................11
3.5
DISINFECTION PROCESS FAILURES ................... ......... ................... .................. .................. ................... ................... .........12 12
3.6
SSR CONTROL ................... ......... ................... .................. ................... ................... .................. ................... ................... .................. .................13 ........13
3.7
CO2 CYC CYCLE LE ................................. ................................................. ................................. ................................. .................................. .........................14 .......14
SECTION 4 - SPARE PART REPLACEMENT .....................................................................15 4.1 ACCESS TO THE COMMAND AND CONTROL UNIT ................... ......... ................... .................. ...............15 ......15 4.2
REPLACING THE MAIN PCB .................. ......... .................. ................... ................... ................... ................... .................. ...............15 ......15
4.3
REPLACING THE COMMAND AND DISPLAY PCB .................. ......... ................... ................... .................. .........15 15
4.4
REPLACING SAFETY THERMOSTAT .................. ......... .................. .................. ................... ................... .................. ...........16 ..16
4.5
REPLACING TEMPERATURE SENSOR (Pt 100) IN THE JACKET ................... .......... ............16 ...16
4.6
REPLACING TEMPERATURE SENSOR (Pt 100) ON THE DOOR ................... ......... ..............17 ....17
4.7
REPLACING THE HEATER .................. ........ ................... ................... ................... .................. .................. ................... ................... .........17 17
4.8
REPLACING THE HEATER ON THE DOOR .................. ......... ................... ................... .................. ................... ...........18 .18
4.9
REPLACING GLASS DOOR .................. ......... ................... ................... ................... ................... .................. .................. .................18 ........18
4.10
REPLACING GLASS DOOR LOCK .................. ......... ................... ................... .................. ................... ................... ...............19 ......19
2
4.11
REPLACING PLASTIC PANEL ................... .......... ................... ................... .................. ................... ................... .................. ............19 ...19
4.12
REPLACING MAGNETIC GASKET .................. ......... ................... ................... .................. ................... ................... ...............20 ......20
4.13
REPLACING BIOLOGICAL FILTER .................. ......... ................... ................... .................. ................... ................... ...............20 ......20
4.14
REPLACING THE DOOR SWITCH ................... .......... ................... ................... .................. ................... ................... ...............20 ......20
4.15
REPLACING FAN/MOTOR ................... ......... ................... ................... ................... .................. .................. ................... ................... .........21 21
4.16
REPLACING UV LAMP ................... ......... ................... .................. ................... ................... .................. ................... ................... ...............21 ......21
4.17
REPLACING IR SENSOR ................... .......... ................... ................... .................. ................... ................... .................. ................... ...........22 .22
4.18
REPLACING CABLE HEATER....................... HEATER.............. ................... ................... .................. ................... ................... .................. .........23 23
4.19
REPLACING REGULATOR .................. ........ ................... ................... ................... .................. .................. ................... ................... .........23 23
4.20
REPLACING SOLENOID VALVE ................... .......... ................... ................... .................. ................... ................... .................. .........24 24
4.21
REPLACING THE PUMP ................... ......... ................... .................. ................... ................... .................. ................... ................... ............25 ...25
4.22
REPLACING FUSE PCB .................. ......... ................... ................... .................. ................... ................... .................. ................... ..............25 ....25
4.23
REPLACING SSR ................... ......... ................... .................. ................... ................... .................. ................... ................... ................... ..............26 ....26
4.24
REPLACING ELECTRONIC ELECTRONIC RELAY ................... ......... ................... .................. ................... ................... ................... ..............26 ....26
SECTION 5 - DRAWINGS AND DIAGRAMS .......................................................................27 5.1 ELECTRICAL CIRCUIT DIAGRAM ................... .......... ................... ................... .................. ................... ................... ...............27 ......27 SECTION 6 - SPARE PARTS LIST ......................................................................................28 5.2
SCHEMATIC FIGURE AND PART LIST ................... .......... ................... ................... .................. .................. .................28 ........28
6.1
SPARE PARTS LIST.................. ........ ................... ................... ................... .................. .................. ................... ................... ................... ...........32 .32
Factory Saracalar Mahallesi, Saracalar Kümeevleri No:4/2 (Eski Esenboğa Yolu 22.Km) Akyurt 06750 ANKARA-TURKEY Tel: 00 90 312 399 28 30 (3 lines) Fax: 00 90 312 399 21 97 e-mail:
[email protected] e-mail:
3
SECTION 1 - INTRODUCTION 1.1 PURPOSE OF THE SERVICE MANUAL This manual includes servicing and maintenance information for EC 160 CO 2 Incubator. It is prepared to be used by technicians who were formerly trained by Nuve. This manual informs the technicians about the operating principles, diagnosing and repairing methods and spare part replacing. If any problem is detected which is not identified in this manual, please contact to Nuve Servicing Team.
1.2 GENERAL PURPOSE OF THE UNIT The command and control units are located on the right front top and on the left side of the metal sheet at the back. The heating function is performed by the heater on the door, the heaters assembled at the bottom of the chamber and to the half of the sides of the chamber. Heating function is also supported by the jacket heater. The safety thermostat sensor is mounted to the back cover of the sterilization chamber and the thermocouple is mounted to upper left side of the chamber. EC 160 CO 2 Incubator is microprocessor controlled and the unit has triple insulation that consists of glass wool, aluminum sheet and air gap.
4
SECTION 2 - OPERATING PRINCIPLES 2.1 GENERAL OVERVIEW CO2 incubators can be examined in 5 main categories:
Power supply Command and control unit Heating unit Humidity unit CO2 gas unit.
2.2 EXPLANATIONS OF THE FUNCTIONS 2.2.1
Power Supply Values
Power supply values are listed in Table 1. Table 1
Model EC 160 2.2.2
Fuse PCB 5A
Power Consumption 900 W
Power inlet
Heater type
230 V AC
Pipe type (Stainless) 2x125 W, 1x600 W (in series)
Command and Control Unit
2.2.2.1 Main PCB The main PCB operates on the basis of PID (Proportional + Integral + Derivative) controlling system. All command and control elements excluding safety thermostat are connected to the main PCB. These are:
Temperature sensor Command and display PCB Power supply terminals of heaters CO2 gas sensor.
2.2.2.2 Programming and Operating Control Panel Figure 1 illustrates the control panel functions. Functions of the F1, F2, F3, F4 buttons are correspond to the commands on the screen. For instance, F1 button is used to reach ‘MENU’ and F’ button is used to reach ‘SNSR’ option according to Figure 1.
For more information, please refer to the t he user’s manual.
5
Figure 1
2.2.3
Heating Unit
Heating is performed by the stainless steel pipe heaters assembled at the bottom of the chamber and to the half of the sides of the chamber and heater on the door. It is supported by the jacket heater, as well. Heating unit functions with two 125 W heaters and a 600 W heater which are connected in series. 2.2.4
Humidification Unit
Distilled water placed on the tray in the chamber provides 95% RH humidity at 37 ºC. 2.2.5
CO2 Gas Unit
CO2 gas can be controlled up to 20% by using an external tube. 2.2.5.1 IR Sensor IR sensor reads the CO2 amount in the chamber. The hose through which CO2 gas passes is surrounded by a heating cable and the hose is located on the inlet of the IR sensor. The heating cable warms up the cold CO 2 gas so that sensor is able to read the amount of CO 2.
6
SECTION 3 - SERVICING CAUTION: Before servicing the instrument, please take the necessary precautions for your CAUTION: Before health. Please respect to the warnings on the unit!!
3.1 GENERAL OVERVIEW Various troubleshooting that can be encountered with EC 160 unit can be fixed with the guidance of the tables provided in the following sections (Section 3.2, 3.3, 3.4 and 3.5). Majority of the potential problems can be determined by the help of a multimeter. The components on the main PCB or command and display PCB cannot be replaced even the failure is caused by one of them. In such cases, please send the ffailed ailed PCB to the factory service along with a note on which the failure explanations are written. Please make sure that the failure is not caused by weak wire and terminal connections before replacing the PCB or any command and control element. 3.1.1
PERIODIC MAINTENANCE MAINTENANCE
It is highly highly recommended recommended to replace the filter inside inside the chamber chamber once in a year year and
replace the filter in the back side of the unit in every 6 months. The period of changing filter depends on the amount of ambient air pollution and frequency of usage. (See Section 4.13) The air circulation pump should be replaced replaced in in every 3 years. (See Section Section 4.21) 4.21) nUVeRay™ UV lamp should be replaced once in a year. (See Section 4.16) Please refer refer to service service manual manual for further instructions instructions regarding regarding periodic periodic maintenance. maintenance. (See Section 4.15)
7
3.2 GENERAL FAILURES FAILURE 1) On/off switch is ON but LED is OFF and the display is blank.
2) The on/off switch and LED are ON but the display is blank or some segments are blank.
PROBABLE CAUSES Power supply failure.
SOLUTION Check whether mains voltage is supplied. Check whether the terminals t erminals and power supply sockets are well connected.
The glass fuse has blown.
Replace the causes glass fuse. Detect what short circuit and blowing the fuse, and then fix it. Replace the On/Off switch. Disconnect this connection cable and re-connect it carefully. Replace the cable with socket. Replace the connection cable.
On/off switch is defective. The main PCB / display PCB connection cable is not connected properly. Cable with socket is defective. The main PCB / display PCB connection cable is defective. The main PCB is defective.
3) 3) The The on/off switch is OFF but LED is ON.
The on/off switch cable connection is improper.
4) The fuse has blown permanently.
Short-circuit exists.
The main PCB is defective. message 5) ‘Erroron 10’the appears screen.
Door is open more than two minutes. Door switch is defective. The main PCB is defective.
Replace the main PCB. (See page 16) Check the connections and connect them properly. (Connect the cables from the main PCB to the 1 position of the switch and the cables from mains to the 0 position.) Check the heating unit elements for short circuit. If short exists, then replace the corresponding correspondin g element. Check the electrical terminal t erminals s and cables for short circuit. Replace the main PCB (see page 16) Check whether glass door is closed and gasket touches the chamber properly. Replace the door switch. Replace the main PCB (see page 16).
8
3.3 TEMPERATURE REGULATION OPERATING FAILURE FAILURE 1) 1) Actual Actual temperature in the chamber differs from the display.
PROBABLE CAUSES Temperature sensor reads incorrectly.
SOLUTION Check that the ending of the temperature sensor does not touch the chamber surface or the samples. Replace the temperature sensor.
Failure of the main PCB calibration.
2) 2) ‘Error 1’ message appears on the display.
Chamber temperature sensor (Pt 100) failure. Check whether the connections are Temperature sensor endings proper. If a failure is detected, replace are defective or connection is it. loose.
The main PCB is defective. 3) 3) ‘Error 2’ message appears on the display.
4) 4) ‘Error 4’ message appears on the display.
Contact to Nuve Factory Servicing Team for necessary calibration procedure.
Replace the main PCB (see page 16).
Door Pt100 sensor failure. f ailure. Temperature sensor endings are defective or connection is loose.
Check whether the connections are proper. If a failure is detected, replace it.
The main PCB is defective.
Replace the main PCB (see page 16).
The failure when chamber temperature is higher than the maximum limit. The heating terminal SSR on the main PCB is defective.
Check heating SSR outlet with a multimeter. If it shows 12 Vdc, replace the main PCB.
SSR is defective.
Check whether SSR is defective. (See Section 3.6)
The main PCB is defective.
Replace the main PCB (see page 16).
9
FAILURE 5) 5) ‘Error 5’ message appears on the display.
PROBABLE CAUSES
SOLUTION
The failure when chamber temperature is lower than the minimum limit. Excessive heat loss. Check whether the glass door is closed properly and chamber gasket is tight. Adjust the safety thermostat thermostat to a The safety thermostat is adjusted to a temperature lower value higher than the set than the set temperature or it is temperature; if it is defective replace defective. the safety thermostat. Heater is defective. Check the heater resistances with multimeter. Replace it if they are defective. The heating SSR terminal on Check heating SSR outlet with a the main PCB is defective. multimeter. If it does not show 12 Vdc, replace the main PCB. SSR is defective. Check whether SSR is defective. (See Section 3.6) The main PCB is defective. Replace the main PCB (see page 16). Temperature sensor endings Reconnect them properly. connections wrong.
6) 6) ‘Error 6’ message appears on the display.
Failure when door temperature is higher than the maximum limit. Door heater SSR outlet on the t he Check the door heater SSR outlet main PCB is defective. on the main PCB with a multimeter. If it shows 12 V dc, replace the main PCB. SSR is defective. Check whether SSR is defective. (See Section 3.6) The main PCB is defective. Replace the main PCB (see page 16).
7) 7) ‘Error 7’ message appears on the display.
Failure when door temperature is lower than the minimum limit. Surface thermostat thermostat is defective. Replace the surface thermostat, ifif it is defective. Heater is defective. Check the heater resistances with multimeter. Replace it if they are defective. Door heater SSR outlet on the t he Check the door heater SSR outlet main PCB is defective. on the main PCB with a multimeter. If it does not show 12 V dc, replace the main PCB. SSR is defective. Check whether SSR is defective. (See Section 3.6) Excessive heat loss. Check whether the glass door is closed properly and chamber gasket is tight. Main PCB is defective. Replace the main PCB (see page 16).
10
3.4 CO2 GAS CONTROL FAILURES FAILURE 1) 1) ‘Error 3’ message appears on the display.
2) 2) ‘Error 8’ message appears on the display.
3) 3) ‘Error 9’ message appears on the display.
PROBABLE CAUSES SOLUTION IR gas sensor is defective. Loose connection between Check socket connections and make the sensor and the main PCB. them proper. Flat socket cable between the Replace the flat cable. sensor and main PCB is defective. Main PCB is defective. CO2 amount is higher than the Calibration of the sensor is corrupted. Regulator setting range is defective. Solenoid valve is defective.
Replace the main PCB (see page 16). maximum limit. Make zero calibration. Check the regulator.
Clean the solenoid valve and replace it, if it is defective. Pump is defective. Replace the pump. SSR is defective. Check SSR outlets with a multimeter. multimeter . Replace it, if it is defective. Main PCB is defective. Replace the main PCB (see page 16). Failure when CO2 amount is lower than the minimum limit. Check the gas in the CO 2 tube from the pressure regulator. Check whether gas passes from regulator to the unit. Check the hose connection between pressure regulator exit and CO 2 inlet of the unit for leakage. leakage. Ensure that the glass door is closed and it presses the chamber gasket properly. properly. The pump is defective. Replace the pump. Main PCB pump terminal outlet is defective. CO2 supply solenoid valve is defective. CO2 supply solenoid valve SSR is defective. CO2 supply solenoid valve SSR terminal on the main PCB is defective.
Check the main PCB pump outlet with a multimeter. If it does not show 220 Vac, replace the main PCB (see page 16). Clean the solenoid valve core. Replace it, if it is defective. Check SSR (See Section 3.6). Check the CO2 supply solenoid valve SSR terminal outlet with a multimeter. If it does not show 12 V dc, replace the main PCB (see page 16).
11
3.5 DISINFECTION PROCESS FAILURES FAILURE 1) 1) ‘Error 11’ message appears on the display.
PROBABLE CAUSES
SOLUTION
Failure occurs when the temperature drops below 88 ˚C at least for 2 minutes after disinfection process starts. Disinfection process stops. Display goes back to regular working display. Gas thermostat setting range is defective.
Set the thermostat to a higher temperature.
Chamber heater SSR is defective.
Check the SSR (See Section 3.6).
Chamber heater SSR outlet on the main PCB is defective.
Check the chamber heater SSR outlet with a multimeter. If it does not show 12 V dc, replace the main PCB (see page 16).
Circulation motor is defective. defective.
Check the circulation circulation motor with a multimeter. Replace it, if it is defective. Check the cable terminal connections are proper.
Heaters are defective.
Check the heater resistance values with a multimeter. Replace it, if it is defective.
Temperature sensor reads incorrectly.
Contact to Nuve factory servicing team. Replace the temperature sensor.
2) 2) ‘Error 12’ message appears on the display.
Failure occurs when the temperature gets higher than 95 ˚Cat least for 2 minutes after disinfection process starts. Disinfection Disinfection process stops. Display goes back to regular working display. SSR is defective.
Check SSR. (See Section 3.6).
Chamber heater SSR outlet on the main PCB is defective.
Check the chamber heater SSR outlet with a multimeter. If it does not show 12 V dc, replace the main PCB (see page 16).
Temperature sensor reads incorrectly.
Contact to Nuve factory servicing team. Replace the temperature sensor.
12
3.6 SSR CONTROL
Figure 2
SSR has 4 terminals (Figure 2). Terminal 1 and 2 are used for phase flow, Terminal 3 and 4 are connected to the main PCB. Terminal 3 is connected to the (+) end and terminal 4 is connected to the (-) end. Terminal 1 is the phase inlet and terminal 2 is the t he phase outlet. DC voltage supplied by SSR to the Terminal 3 and 4 enable phase flow by causing short circuit on the terminal 1 and 2. If there is no voltage on Terminal 3 and 4, terminal 1 and 2 are open circuit. Circuit component to be controlled (heaters, compressor, solenoid valve, etc.) should be connected to Terminal 2. 2. Following states indicates the SSR failure: State - 1: There is voltage on the main card and Terminal 1 and 2 are open circuit, State - 2: There is no voltage on the main card and Terminal 1 and 2 are short circuit. At State-1, if a heater is connected to Terminal Terminal 2, the unit doe does s not heat. At State-2, if a heater is connected to Terminal 2, the unit cannot control the heating and it overheats. Controlling State-1: When the device is on the OFF position, disconnect Terminal 1 from the main card. The terminal of the cable must not touch to anywhere, please isolate it. If the unit does not heat, set it to high temperature and run it. Check Terminal 3 and 4 whether there is DC voltage or not. If there is DC voltage, it means that the main card works properly. In this case, check Terminal 1 and 2 whether there is short circuit. If there is no short circuit but there is open circuit, it means SSR is defective. SSR is not defective on the following situations: - There is DC voltage on Terminal 3 and 4, short circuit on Terminal 1 and 2, - There is no DC voltage on Terminal 3 and 4, and open circuit on Terminal 1 and 2. Controlling State-2: When the device is on the OFF position, disconnect Terminal 1 from the main card. The terminal of the cable must not touch to anywhere, please isolate it. If overheating problem is encountered, set the temperature to a value smaller than the displayed one or do your measurements after temperature exceeds the set temperature value. Check whether there is DC voltage on Terminal 3 and 4. If there is no DC voltage, the 13
main card does not work properly. In this case, check Terminal 1 and 2 whether there is open circuit. If there is no open circuit but there is short circuit, then SSR is defective. SSR is not defective on the following situations: situations: - There is DC voltage on Terminal 3 and 4, short circuit on Terminal 1 and 2, - There is no DC voltage on Terminal 3 and 4, and open circuit on Terminal 1 and 2.
3.7 CO2 CYCLE
Figure 3 - CO2 Cycle
14
SECTION 4 - SPARE PART REPLACEMENT Caution: Unplug the unit before replacing any part!! Caution:
4.1 ACCESS TO THE COMMAND A AND ND CONTROL UNIT
Remove the cover metal sheet on the right side.
4.2 REPLACING THE MAIN PCB
Figure 4
Disconnect the command and display PCB / main PCB connection connectio n cable (18) from the main PCB (25). Remove all the terminals connected to main PCB clamps. Remove the 4 connection clamps on the edges and then the main PCB. Place the new main PCB on the connection clamps and make the terminal connections according to the electrical diagram provided in Section 5. Plug the command and display PCB / main PCB connection cable (18).
4.3 REPLACING THE COMMAND AND DISPLAY PCB
Disconnect the command and display PCB / main PCB connection cable from the main PCB (25). Remove the 4 connection clamps on the edges and then the PCB. Place the new command and display PCB. Check that that the display keys and the led lamps meet their their places on the panel. Connect the command and display PCB / main PCB connection connectio n cable (18).
15
4.4 REPLACING SAFETY THERMOSTAT
Figure 5
Unscrew upper back back cover cover sheet sheet metal screws and remove remove the back sheet metal. metal. Disconnect the power supply socket terminals on the back cover sheet. Loosen the safety safety thermostat thermostat sensor sensor that is is assembled assembled on the chamber chamber back back side and remove it. Disconnect the cable terminals on the safety thermostat. Unscrew the two connection screws which fix the safety thermostat and pull the safety thermostat backwards. backwards. Loosen the screw of adjustment button on adjustment shaft and then remove it. Remove the chassis chassis connection connection item which which is con connected nected to the safety thermostat body. While assembling assembling the new new safety thermostat, do do not not bend or break break the capillary capillary cable. cable.
4.5 REPLACING TEMPERATURE SENSOR (Pt 100) IN THE JACKET
Remove the two back cover cover metal sheet and and the cover sheet sheet metal inside the door. door. Disconnect the temperature sensor’s ending from the main PCB. Remove the temperature temperature sensor sensor in the chamber from the clamping clamping metal metal sheet sheet and pull it from the back. Place the new temperature sensor ending to the chamber. Connect the new temperature temperature sensor sensor terminal connections according to electrical circuit diagram (See Section 5). Ensure that temperature temperatu re sensor ending has no no contact with chamber jacket and clamping metal sheet.
16
4.6 REPLACING TEMPERATURE SENSOR (Pt 100) ON THE DOOR
Figure 6
Disconnect the ending ending of the tempera temperature ture sensor sensor on the door from the main PCB. (See Section 5) Remove the inner sheet metal of the door. Remove the glass wool wool insolation. insolation. Make sure that glass wool wool is not not damaged for reuse. Unscrew the screws screws of the nut on the temperature temperature sensor sensor ending. ending. Remove Remove the nut and then take out the Pt100. Place the new sensor’s black part to that position and ensure that it contacts to the heater on the door. Fasten the nut which is unfastened before. Place the glass wool which is removed before. Assemble the inner sheet metal of the door. Connect the new temperature temperature sensor sensor terminal connections according to electrical circuit diagram (See Section 5).
4.7 REPLACING THE HEATER
Remove the back metal sheet. Disconnect heater terminal connection cables. Unfasten the nuts which connect the heater to the chassis. chassis. Remove the temperature sensor.
Unscrew the chamber screw screw er that is on onleft top right of theside, Remove the chamb inner inner lethe ft side, sichamber. de, bottom bottom and top metal sheets. sheets. Remove the heater. Place the new heater and fasten itit with with nuts from the back. Connect the heater terminal connection cables.
17
4.8 REPLACING THE HEATER ON THE DOOR
Figure 7
Disconnect the ending ending of of the temperature temperature sensor on the door from from the main PCB. PCB. (See Section 5) Remove the inner sheet metal of the door. Remove the glass wool insolation. Make sure that glass wool is not damaged for reuse. Remove the protection metal sheet of the heater. Remove the heater heater by pulling it out out between between the micanite micanite sheets. sheets. Place the new heater between between the micanite micanite sheets sheets and put back back the protection sheet metal. Place the glass wool which is removed before. Assemble the inner sheet metal of the door. Connect the new new heater terminal connections according to electrical electrical circuit diagram (See Section 5).
4.9 REPLACING GLASS DOOR
Figure 8
Remove the hinges of the glass door. Assemble the new glass door on the hinges.
18
4.10 REPLACING GLASS DOOR LOCK
Figure 9
Unscrew the lock shaft screw and remove the shaft. Unfasten the lock nut and remove the lock body. Place the new lock body in its position on the door glass and fasten it with with a nut. Place the lock shaft shaft and screw screw it. Adjust Adjust the length length of of the lock shaft shaft to fix the lock lock to its position.
4.11 REPLACING PLASTIC PANEL
Figure 10
Pull out the plastic panel from the panel panel sheet. (4) Clean the surface surface of the panel panel with cleaners, e.g. alcohol. Stick the new plastic panel by meeting meeting the key places on the sheet. sheet.
19
4.12 REPLACING MAGNETIC GASKET
Remove the connection connection screws on the gasket inner surface. (2) Pull the magnetic magnetic gasket from the door inner sheet, separate them. Assemble the new magnetic gasket on the door inner sheet. Place the door door inner inner sheet to its place and assemble it.
4.13 REPLACING BIOLOGICAL FILTER
Assembly of the biological biological filter in the chamber: o Assemble the biological filter as shown in Figure 11. 11.
Figure 11
Assembly of the biologic biological al filter at the back of the unit: o Assemble the biological biological filter at the “filter” inlet at th the e back of the unit.
4.14 REPLACING THE DOOR SWITCH
Figure 12
Loose the door switch on the sides with an electrician screwdriver. Disconnect the cables of the door switch. Replace the old door switch with a new door switch. Connect the cables of the new door switch. Place the new door switch into its position.
20
4.15 REPLACING FAN/MOTOR
Figure 13
Remove the back side cover metal sheet. Remove the insulation material around the motor. Disconnect the circulation motor connection cable terminals. Unscrew the screws on the edges of of heater protection sheet metal in the chamber. Dismantle the motor propeller. propeller. (Warning: Rotate the motor propeller to the clockwise direction while dismantling ) Unscrew the circulation motor chassis screws. Take out the circulation motor from the backside of the unit. Place the new new circulation circulati on motor from the back side and fix it with screws.
4.16 REPLACING UV LAMP
Figure 14
Unplug the UV lamp power cable from the socket. Take out the UV lamp unit from the glass door of the unit. Place the new UV lamp to its position in the glass door. Plug the UV lamp power power cable in the socket. 21
4.17 REPLACING IR SENSOR
Figure 15
Disconnect the flat cable of the IR senso sensorr from the main main PCB. (See Section Section 5) Remove the square square shaped shaped sheet sheet metal which fixes the IR sensor sensor to the sheet sheet metal of the unit. Disconnect the hose hose connections connections on the bottom of the unit. unit. Unscrew the 4 screws on the square shaped sheet metal. Remove the unions of the hoses. Place the new sensor. Connect the hoses with unions. Screw the square shaped sheet metal with 4 screws. screws. Screw the square square shaped shaped sheet metal metal to the sheet sheet metal of the unit. unit. Connect the flat cable of the IR sensor sensor to the main main PCB. (See Section Section 5)
22
4.18 REPLACING CABLE HEATER
Figure 16
Disconnect the terminal connections of the cable heater. Remove the cable heater with the hose. Place the new cable heater.
4.19 REPLACING REGULATOR
Disconnect the hoses hoses of the regulator regulator by unfastening unfastening the unions. Take out out the manometer from the body.
Figure 17
Rotate the black adjustment handle which is placed on the bottom of the metal sheet to which regulator body is connected and remove it. Unfasten the grey nut on the back. Remove the regulator body from the metal sheet.
23
Figure 18
Place the new regulator body on on the metal she sheet. et. Fasten the grey nut and place the black adjustment handle. Place the manometer manometer on the regulator body by rotating it. Connect the hoses to the regulator with unions. Connect the regulator regulator cable cable terminal terminal connections connections to the main PCB. PCB. (See Section 5)
4.20 REPLACING SOLENOID VALVE
Figure 19
Unscrew the solenoid valve bobbin socket screw and separate it.
Disconnect the solenoid valve hose connections. Unscrew the assembly screw of the solenoid valve. Remove the connection adaptors on the solenoid valve. Assemble the connection adaptors to the new solenoid valve inlet and outlet. Fix the new solenoid valve on the sheet metal and reconnect the hoses which are disconnected before. Connect the solenoid solenoid valve valve cable cable terminal terminal connections connections to the main PCB. PCB. (See Section 5)
24
4.21 REPLACING THE PUMP
Figure 20
Disconnect the pump cable terminal connections from the main PCB. PCB. (See Section 5) 5) Disconnect the hoses of the pump carefully. carefully. Unscrew the screws of the pump in order to remove it. Assemble the new new pump pump on on the metal sheet and connect the hoses. hoses. Connect the pump cable terminal connections to the main PCB. PCB. (See Section 5)
4.22 REPLACING FUSE PCB
Fuse PCB
Figure 21
Disconnect the terminal connections on the fuse PCB. Unscrew the screws screws on the edges edges of the fuse PCB and remove the fuse PCB. Assemble the new new fuse PCB by meeting the assembly assembly points. Connect the fuse PCB terminal terminal connections according according to electrical circuit diagram. diagram. (See Section 5)
25
4.23 REPLACING SSR
Figure 22
Disconnect the SSR cable terminal connections. connections . (See Section 5) Unscrew the screws which fix the SSR to the sheet metal. Assemble the new SSR on the sheet metal. Connect SSR cable terminal connections carefully. carefully. (See Section 5)
4.24 REPLACING ELECTRONIC RELAY
Disconnect the cable terminal connections of the electronic relay. (See Section 5) Unscrew the screws which fix the electronic relay on the sheet metal. Assemble the new relay on the sheet metal. Connect electronic relay cable terminal connections carefully. (See Section Section 5)
26
SECTION 5 - DRAWINGS AND DIAGRAMS 5.1 ELECTRICAL CIRCUIT DIAGRAM
27
SECTION 6 - SPARE PARTS LIST 5.2 SCHEMATIC FIGURE AND PART LIST
Figure 23 - Front View
28
Figure 24 - Left Back View
29
Figure 25 - Right Side View
31. Glass 31. Glass Wool
Figure 26 - Three Layer La yer Insulation
30
Figure 27 - Inner Jacket View
31
6.1 SPARE PARTS LIST NO ITEM NAME 1 Control Panel
ITEM CODE Z15.G 05 040
QTY 1
2
689x879 mm Chamber Gasket
Z15.C 03 198
1
3
Biological Filter (Inside the chamber)
Z12.F 06 003
1
4
Plastic Panel
Z15.P 15 234
1
5 6
Shelf 602x784 mm Glass Door
Z11.R 01 154 Z15.C 01 057
3 1
7
UV Socket
Z21.S13 011
1
8
Door Switch
Z12.A 03 040
1
9
Humidity Tray (Bain-Marie Tray 25x35x5)
Z12.T 04 027
1
10
CO2 External Measurement Measurement Port
Z11. R02 420
1
11
RS 232/Printer Port
Z15.K 01 204
1
12
Remote Alarm Output
Z12. F07 021
1
13
CO2 Tube Inlet
Z11. R02 422
1
14
Biological Filter (back of the unit)
Z12.F 06 053
1
15
Safet Thermostat (30-110 ºC)
Z12.T 09 113
1
16 17
Mains Power Switch Power Supply Inlet
Z12.A 03 052 Z12.S 13 014
1 1
18
Flat Cable with socket
Z15.K 01 139
1
19
IR Sensor (CO2 Concentration Concentrati on M400)
Z12.S 20 018
1
20
Biological Filter (Right Side)
Z12.F 06 003
1
21
Pump (230 V 50 Hz Charles)
Z12.P 12 017
1
22
Heater Cable (SDK4234 30W)
Z13.K 39 001
1m
23 24 25 26 27 28 29 30 31 32 33
Solenoid Valve (3/2" Sirai) Relay - SSR (4-32 VDC Ç28-280 VAC) Main PCB (MP Controlled Thermostat) Solenoid Valve (Sirai) Regulator (Full components) Electronic Relay (1x25A) Electronic PCB - Transformer Fuse PCB Glass Wool 3 cm (with folio) Pt100 (inside the jacket) Fan - Motor (EBM Papst)
Z12.V 01 083 Z12.R 07 028 Z15.T 09 118 Z12.V 01 084 Z11.R 11 010 Z12.R 07 013 Z15.E 05 087 Z15.E 05 048 Z13.I 10 032 Z15.I 01 044 Z12.F 04 024
1 3 1 1 1 1 1 1 2.55m2 1 1
34 35 36
Stainless Heater (125 W) Stainless Heater (600 W) Pt100 (inside the door)
Z15.I 02 172 Z15.I 02 182 Z15.I 01 076
2 1 1
32
