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Table of Contents

RC-28S/RC-24 Service Manual Supplement

Paragraph Page

Part 1: RC-24 Service Information ............................. 1

Description ........................................... 1

Operation ............................................ 1

Repair & Replacement................................... 1

Diagnostics ........................................... 1

Calibration ........................................... 2

Illustrated Parts. ....................................... 2

Part 2: Voltage Conversion................................... 3

Part 3: Drive Control & Power Distribution Theory ................. 5

Drive Specifications ..................................... 5

General Description of Drive Control Electronics ............... 5

Drive System Performance................................ 10

Power Distribution Box Theory ............................ 12

Electronic System Glossary ............................... 14

Part 4: Repair and Replacement............................... 18

Relay Printed Circuit Board Replacement..................... 19

Circuit Breaker/Fuse Switch Replacement. ................... 20

Solid State Relay Replacement............................. 20

Changing the Vacuum Pump Oil ........................... 21

Drive Motor Replacement................................. 21

Drive Motor Fan Replacement ............................. 27

Drive Control Module Replacement ......................... 27

Part 5: Diagnostics & Fault Troubleshooting ..................... 28

Screen 1. Fault Messages ................................ 28

Screen 2, User DIAGNOSTICS ............................. 29

Screen 3, Service DIAGNOSTICS ........................... 29

Part 6: Operational Checks & Troubleshooting. ................... 97

Part 7: Printed Circuit Boards & Schematic Diagrams .............. 107

Part 8: Illustrated Parts ..................................... 147

List of Illustrations

Figure Page

1 RC-24 DIAGNOSTIC Mode Access .......................... 1

2 Voltage Conversion ..................................... 4

3 Input and Output Signals. Drive Control Module ............... 8

4 Power Distribution Box Input/Output ....................... 13

5 Parts Identification. Vacuum Pump Oil Change ................ 22

6 Parts Location, Drive Motor Replacement..................... 24

7 Bad AC Power Relay, Flow Chart ........................... 31

8 Bad Brake Monitor Circuit. Flow Chart ...................... 33

List of Illustrations (continued)

Figure Page

9 Bad Drive Accel. Flow Chart .............................. 34

10 Bad Min Speed Monitor. Flow Chart. ........................ 35

11 Bad Speed Control. Flow Chart ............................ 36

12 Calrod Overtemp, Flow Chart ............................. 37

13 Can't Reach Full Vacuum, Flow Chart ....................... 38

14 Ctrlr Drive Enable Out. Flow Chart ......................... 39

15 Door Locked Switch. Flow Chart ........................... 41

16 Door Not Closed. Flow Chart .............................. 43

17 Door Not Latched. Flow Chart ............................. 44

18 Door Not Locked. Flow Chart.............................. 45

19 Door Open Switch, Flow Chart. ............................ 46

20 Drive Enable (Ctrlr off). Flow Chart ......................... 47

21 Drive Enable (H & C off), Flow Chart ........................ 48

22 Drive Enable (Host off). Flow Chart ......................... 49

23 Drive Failed To Start, Flow Chart. .......................... 51

24 Drive Still Enabled. Flow Chart ............................ 55

25 Dv-Enab FALSE Refused, Flow Chart. ....................... 56

26 Dv-Enab TRUE Refused. Flow Chart ........................ 57

27 High Chamber Temp, Flow Chart. .......................... 58

28 High Drive Temperature. Flow Chart ........................ 59

29 Improbable Speed Chng, Flow Chart ........................ 60

30 Inertia Out of Range. Flow Chart ........................... 61

31 Inertia Too High. Flow Chart .............................. 62

32 Inertia Too Low, Flow Chart............................... 63

33 Inoperable Vacuum, Flow Chart............................ 64

34 Instrument Overspeed. Flow Chart ......................... 65

35 Loss of Tachometer, Flow Chart............................ 67

36 Low Chamber Temp. Flow Chart ........................... 69

37 No Ctrlr Drive Disable. Flow Chart.......................... 70

38 No Ctrlr Drive Enable. Flow Chart .......................... 71

39 No Deed Detected. Flow Chart............................. 72

40 No Door Unlock, Flow Chart .............................. 73

41 No Drive Enable (H & C). Flow Chart ........................ 75

42 Open Winding Sensor. Flow Chart .......................... 77

43 Rotor Overspeed. Flow Chart .............................. 78

44 Rotor Overtemp, Flow Chart .............................. 79

45 Shorted Winding Sensor. Flow Chart ........................ 83

46 Speed Overshoot Trap, Flow Chart. ......................... 84

47 Temp Out of Range, Flow Chart............................ 85

48 Vacuum Loss. Flow Chart ................................ 87

49 Vacuum Release Failure, Flow Chart ........................ 89

50 Warn - Marginal Vacuum, Flow Chart ....................... 91

51 Warning - Hot Gas Failed. Flow Chart ....................... 93

52 Warning - Low Accel. Flow Chart........................... 95

53 Warning - Poor Brake. Flow Chart .......................... 96

54 LED Supply Check. Flow Chart ............................ 103

List of Illustrations (continued)

Figure Page

55 24V Supply Check Flow Chart ............................. 105

56 Motor Winding Continuity Check Flow Chart .................. 106

57 System Wiring Diagram .................................. 109

58 System High Voltage Wiring Diagram........................ 113

59 Schematic. Controller Printed Circuit Board, 59855-0 ........... 117

60 Component Location. Controller Printed Circuit Board. 59855-0 ... 129

61 Schematic, Relay Printed Circuit Board. 59745-0 .............. 139

62 Component Location. Relay Printed Circuit Board, 59745-0....... 141

63 Wiring Diagram. Power Distribution Box ..................... 145

64 Console and Cabinet Assembly, Illustrated Parts ............... 148

65 RC-28S Main Assembly. Illustrated Parts. .................... 150

66 Power Distribution Box Assembly. Illustrated Parts ............. 152

67 Wiring Harness Identification. ............................. 153

List of Tables

Table Page

1 Drive Control Module and Controller Interface Signals........... 7

2 Drive Control Module Signal Descriptions .................... 8

3 Electronic System Glossary ............................... 14

4 Lights, Relay Control P. C. Board........................... 97

5 Lights. Controller P. C. Board ............................. 98

6 Lights. Drive Control Module .............................. 100

7 Control Logic Signals ....................................111

8 Component Identification. Controller P. C. Board, 59855-0 ....... 131

9 Component Identification. Relay P. C. Board, 59745-0 ........... 142

10 Parts List, Console and Cabinet Assembly .................... 149

11 Parts List, RC-28S Main Assembly.......................... 151

12 Parts List, Power Distribution Box Assembly .................. 152

SORVALL® Centrifuges RC-28S/RC-24 Service Manual

Supplement

Part 1: RC-24 Service Information

a. Description

The RC-24 Centrifuge is a superspeed version of the RC-28S SUPRAspeed® Centrifuge

with the following differences:

• no vacuum, system,

• no SPIN-RIGHT® Rotor Management System,

NOTE

Since the RC-24 does not have a vacuum system or a SPIN-RIGHT® Rotor

Management system (URR), please ignore all references to these throughout

the manual.

• a top speed of 24 000 rpm with maximum g force of 60 028 (when used with the

SORVALL SE-12 Rotor),

• no user accessible DIAGNOSTIC mode, and

• no CALCULATE mode.

b. Operation

The operation of an RC-24 is slightly different than operation of an RC-28S because the

PROGRAM key has been replaced by a MODE key and key number access is not required.

For operating procedures, refer to the RC-24 Instruction Manual (PN 59874) or to the RC-

24 Operator's Guide (PN 59870) stored under the control panel.

c. Repair & Replacement

The RC-24 does not have an access panel behind the front cabinet panel. Also. because

it does not have a vacuum system or a SPIN-RIGHT* Rotor Management System, it does

not have an encoder assembly, ultrasonic transducer, URR printed circuit board, door

open switch, or any of the vacuum system components. Therefore, when performing the

repair and replacement procedures in Section 4, pass over any steps that refer to these

parts. The RC-24 has the same Drive Control Module as the RC-28S (SN 9002294 &

above), so the information in the Service Manual Supplement is applicable to the RC-24.

d. Diagnostics

Use the following procedure to access DIAGNOSTICS:

1. Turn the centrifuge power OFF.

2. Remove the front control panel from the control console, then lay the panel on the

centrifuge deck with the keypad facing up.

3. Set the centrifuge to operate in the DIAGNOSTIC mode by moving the two jumpers

stored on the Host P. C. Board to the DIAGNOSTIC position as shown in figure 1.

RC-28S/RC-24 Service Manual

Supplement

SORVALL® Centrifuges

4. Turn the centrifuge power ON, and press the control panel at the location shown in

figure 1 to turn DIAGNOSTICS on.

NOTE

The switch to turn on DIAGNOSTICS is located in the same position as the

RC-28S but there is no key on the control panel to press. Figure 1 shows

the key superimposed over the location of the switch.

HOST BOARD

JUMPER PLUG

POSITIONING

NORMAL

JP-iBn

JP2fln

JP3H°

JP4H°

DIAGNOSTICS

JP1 oo

JP2 0 o

DIAGNOSTICS MODE

SWITCH LOCATION

Figure 1. RC-24 DIAGNOSTIC Mode Access

5. When you are done using the DIAGNOSTIC mode, turn the centrifuge power OFF and

move the two jumpers back to their original position (see figure 1) for storage on the

Host P. C. Board.

6. Reassemble the control console.

e. Calibration

The Controller Drive and the Imbalance System calibration procedures are different for the

RC-24 than the RC-28S. The procedures in Section 8 have been revised to reflect these

changes and new pages are provided in the Update Information (5/91).

f. Illustrated Parts

Following are the new part numbers for the RC-24:

• PN 59867. Bezel, Control Panel. Front (Table 10, item 6);

• PN 59870, Instructions. Operator's Guide, RC-24 (Table 10. item 16);

• PN 59865, Door Plate (Table 10-4. item 20);

• PN 59861. SORVALL RC24/DU FONT oval. front panel decal (Table 10-10); and

• PN 66724, jumper plug. blue. Host P. C. Board.


Part 2: Voltage Conversion


Supplement

NOTE

Use this procedure in place of the one in the Service Manual, Section 2,

paragraph 2-6. Two new labels are required for this procedure: PN 59711,

Power Distribution Box label and PN 59713, Rating Conversion label.

111^^^^

The centrifuge has high ^

electrical shock. For this reason, this procedureshould only be done by a

technician who is familiar with electronics. Before beginning this: proce¬

dure, be sure the centrifuge power is OFF and the power cord is unplugged. I:

1. Turn the centrifuge power OFF. and unplug the power cord.

2. Remove the right-side cabinet panel from the centrifuge.

3. Disconnect all plugs from the top of the Power Distribution Box.

4. Remove the Power Distribution Box mounting screw from the rear of the box, and

remove the box from the centrifuge. Place the box on a clean, flat work surface.

5. Turn the 1 /4-turn fastener on the side of the Power Distribution Box counterclockwise,

and remove the panel from the box.

6. Locate terminal block TB 1. then refer to figure 2 and rearrange the wires to the desired

configuration.

7. Reassemble the Power Distribution Box.

8. Install the Power Distribution Box back in the centrifuge, and secure it in place using

the screw removed in Step 4.

9. Reconnect all plugs to the top of the Power Distribution Box.

NOTE

If changing configuration from one phase to another, raise the front locking

stabilizers and pull the centrifuge away from the wall. Remove existing

power cord from the rear of the centrifuge, and connect new power cord

as shown in figure 2.

10. Write the new specifications (voltage, phase, and frequency) on both labels. Peel the

back off label PN 59713 and stick it over the label on the back of the centrifuge. Peel

the back off label PN 59711 and stick it over the label on the Power Distribution Box,

making sure it doesn't cover any vent holes in the box.

11. Reinstall the right-side cabinet panel. If centrifuge was moved away from the wall.

push it back In location, lower front locking stabilizers, and level the centrifuge.

3


Supplement


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Supplement

Part 3: Drive Control & Power Distribution Theory

NOTE

This information replaces all drive control electronics and power distribu¬

tion theory of operation information in Section 3 of the Service Manual.

a. Drive Specifications

Weight ............................. 15.4 Kg (34 Ib)

Size ............................... 50.2 cm L x 33 cm H x 14.3 cm W

(19.75 in x 13 in x 5.6 in)

Outside dimensions do not include

the mounting tabs.

ac Power Required .................... 187 to 242 Vac. 50/60 Hz,

single phase

Inverter ............................ dc Brushless Drive, 20 A, 3 phase,

6 step. pulse width modulated (PWM)

PWM Frequency (motor power) ........... 22 Khz, ± 5%

PWM Frequency (control signals) ......... 4.8 Khz, ± 5%

Output Current ...................... 0.25 to 20 A, 3 phase

Operating Temperature Range ........... +10 to +50°C

Storage Temperature Range ............. -20 to +85°C

Operating Humidity Range .............. 5 to 95% noncondensing

Cooling............................. Forced air ventilation, vented

out the bottom of the drive

enclosure.

b. General Description of Drive Control Electronics

This is a power inverter motor drive. Its functional purpose is to convert raw single phase

ac power into synchronous 3-phase power to the motor. This is accomplished in several

stages. Following is a description of how the internal power conversion process occurs.

ac to dc Power Conversion

The ac power source may be in the range of 187 to 242 Vac-RMS at a frequency of between

48 to 62 Hz. Only single phase ac is used. Separate ac power ports are provided to the

5


Supplement


Drive Control Module for both motor power and logic hardware power. This provides the

centrifuge with the ability to effect ultimate shutdown control over the motor while the

drive logic hardware remains in a standby mode, should a serious problem develop.

The raw ac power used for the motor passes into a full wave bridge rectifier. From there

it passes through a line choke and into a bank of filter capacitors. The combination of these

components provides a high voltage unregulated dc power source. The choke functions

as a low pass line filter to reduce the effects ofac line noise and surges from passing into

the Drive Control Module. It also serves to help improve the form factor ofac line current

flowing into the Drive Control Module when the motor is in operation.

dc to ac Power Inversion

The high voltage unregulated dc power available in the Drive Control Module must be

converted back to phased ac power in order for the motor to operate. This process is called

inversion. To properly control motor rotation, the drive electronics must synchronize the

application of power precisely with the rotational position of the rotor. This process is

commonly referred to as commutation. The motor used in this centrifuge requires three

phase ac power for commutation.

The three phase ac power used to commutate the motor is phase displaced in time by 120

electrical degrees, not unlike the three phase 50/60Hz ac power available from a power

company. Two major differences exist between them. The first is that the ac power

delivered by the drive is not sinusoidal like that delivered from a power company, but

rather it delivers pulsed square waves. The second major difference is that the drive must

provide variable frequency ac to the motor rather than the fixed frequency ac supplied by

the power company. This feature enables the motor to operate at variable speeds.

The three phase ac power delivered to the motor is developed by an active circuit network

consisting of six power transistors. This network is called the output bridge. In order to

sustain the rotation of the centrifuge, the Drive Control Module continuously processes

and decodes rotor position information. This information is used to sequentially apply

power from the output bridge to the motor.

Motor Torque and Speed Control

It is not sufficient to precisely control the motor through commutation alone. The power

applied to the motor must be carefully metered in order to throttle both torque and speed.

This is accomplished through a technique called pulse width modulation, or PWM.

The PWM technique provides a method of efficient power control through the use of high

frequency output bridge modulation. In effect, as each motor winding is turned ON in

sequence during motor rotation. PWM is superimposed upon the normal commutation

signals. PWM results in the application of power to the motor by chopping it ON and OFF

at a high rate (i.e., 22 kHz). This chopping scheme controls average motor current by

varying the ratio of ON time versus OFF time for each PWM modulation cycle. This

chopping scheme provides proportional output torque from the motor through the direct

adjustment of the average motor current.

The Drive Control Module limits torque by continuously monitoring the electrical current

flowing to the motor and comparing it to the commanded level requested by the control


Supplement

console. The difference between these two levels results in an error signal which is then

converted to a PWM ratio. This PWM ratio is used to modulate the output bridge as

described above.

Motor speed is limited by the control console computer. Using a tachometer signal

supplied by the Drive Control Module, the control console throttles speed through a fine

torque adjustment of the TORQUE DEMAND signal. The drive does not have any means

to regulate motor speed itself.

Control Interface

All input and output communications between the control console and the Drive Control

Module pass through interface connector, J33. which consists of 20 pins. The signals

supplied to the drive from the control console are all electrically isolated from the internal

drive logic hardware. This isolation is provided by means of optical isolators.

The logic signals used to operate the control Interface are all digital in nature. No analog

signals are used. These digital signals are all using +5 volt logic levels.

The Drive Control Module is interfaced with the Controller P. C. Board by a 20-pin ribbon

cable. The signals and their pin designations are listed in Table 1. The signals are

illustrated in figure 3 and described in Table 2.

Table 1. Drive Control Module and

Controller Interface Signals

Pln#

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

Signal Name

REF PWM*

EXTERNAL POWER +5Vdc

BRIDGE ENABLED*

EXTERNAL COMMON

FORWARD ENABLE*

FORWARD ENABLE PWR

ABMINSPD


FULL CHOP*


BRAKE ENABLE*


MOTOR TEMP+

MOTOR TEMP-

SHUNT ACTIVE


NOT USED

EXTERNAL POWER

TACHOMETER

EXTERNAL COMMON

Function

Sets the motor current

+5V optocoupler supply input

FORWARD ENABLE* feedback to Controller

Controller common

Sets forward direction

Led supply for signal FORWARD ENABLE*

Above minimum speed

See pin 2

Selects chopping mode

See pin 2

Selects normal or brake mode

See pin 2

Motor temperature sensing

Motor temperature sensing

Brake activity monitor

See pin 2

See pin 4

Tachometer feedback to Controller

See pin 4

"The asterisk indicates this is a NOT (active low) signal.

7


Supplement


TO CONTROLLER

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BRAKE ENABLE*

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MODULE

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———————


Supplement

Table 2. Drive Control Module Signal Descriptions

(continued)

Signal Description

EXTERNAL

POWER +5Vdc

BRIDGE

ENABLED*

EXTERNAL

COMMON

FORWARD

ENABLE*

FORWARD

ENABLE

POWER

ABMINSPD

The source for the +5 Vdc power used by most of the optical

coupler devices In the drive Interface. The only exception is the

optical coupler used for the FORWARD ENABLE* signal. This

power is sourced from the control console.

This signal originates within the Drive Control Module. It

indicates to the control console that the Drive is commutating

the motor in the forward direction. Conditionally, it is in a low

logic state when there are no faults registered in the Drive,

FORWARD ENABLE* is in a logic low state, and the BRAKE

ENABLE* signal is in a logic high state.

The local ground for all signals sourced into and out of the

drive interface. All voltages at this interface are referenced

to these pins.

This signal originates at the control console. When this signal

is in a logic low state and the BRAKE ENABLE* signal is in a logic

high state, the motor is being commanded to rotate in the for¬

ward direction. Forward motion by the motor will be aborted if

the BRIDGE ENABLED* signal is in a high state or if the BRAKE

ENABLE* signal is in a low state at the same time the BRAKE

ENABLE* signal is in the logic high state.

This is the separate +5 Vdc power supply input pin for exclu¬

sive use by the optical coupler that accepts the FORWARD EN¬

ABLE* signal from the control console. This supply is turned off

if the control console power supply does not operate properly.

If this happens, the Drive will not allow rotor to accelerate nor

will it maintain forward velocity.

The above minimum speed signal which originates within the

Drive Control Module. It is in a logic high state whenever the

motor back EMF voltage indicates that it is rotating above

2000 rpm during a coasting condition. A coasting condition

occurs when rotor is in motion but the control console is not

commanding either a forward drive or brake state. Below 500

rpm, this signal is in logic low state during a coast condition.

Speeds from 500 to 2000 rpm yield an unstable signal seen as

rapid toggling from one logic state to another. Whenever the

control console commands either a forward or brake state and

the Drive is not in a fault condition, ABMINSPD will remain in

an Invalid state. Signal is only valid when the bridge has been

off for >200 ms.

'The asterisk indicates this is a NOT (active low) signal.

• CONTINUED

9

RC-28S/RC-24 Service Manual SORVALL® Centrifuges

Supplement

Table 2. Drive Control Module Signal Descriptions

(continued)

Signal Description

FULL CHOP* Originates at the control console. Full chop is selected when

this signal is in a logic low state. The term full chop refers to

method used for modulating the output bridge. As the motor is

commutated. the standard practice is to modulate either three

or all six of the power transistors used in the output bridge.

When full chop is selected, all six transistors are modulated.

BRAKE EN- Originates at the control console. The brake enable mode is

ABLE* selected when this signal is in a logic low state and the FOR¬

WARD ENABLE* signal is in a logic high state. When the Drive

is commanded to brake and no faults exist, the motor will de¬

celerate. If both a BRAKE ENABLE* signal and a FORWARD

ENABLE* signal are commanded at the same time, the Drive is

not enabled.

MOTOR A separate +5 Vdc supply input pin for exclusive use by the

TEMP+ temperature sensor located in the motor.

MOTOR The return path for the electrical current signal from the temp-

TEMP- erature sensor located in the motor.


c. Drive System Performance

Following is a basic description of some of the operating parameters which should provide

a further understanding of the total system performance. The system consists of the

brushless dc motor drive and control, along with the motor.

Operating Voltages on High Voltage dc Bus (acceleration)

During a standby condition with a nominal 220 Vac-RMS power supplied to the drive

power input, the internal high voltage dc supply bus will be approximately at 305 Vdc.

With a nominal 208 Vac-RMS power applied to the drive power input, the internal high

voltage dc supply bus will be approximately at 288 Vdc. This voltage is unregulated and

may fluctuate with varying ac line conditions. It is also influenced by the centrifuge load

profile, meaning both the type of rotor selected and the speed at which it is rotating. In

general, high speed and larger rotors equate to a somewhat reduced dc bus voltage,

especially during rotor acceleration.

Operating Voltages on High Voltage dc Bus (deceleration)

During deceleration, the high voltage dc supply voltage may temporarily rise to as high as

385 Vdc. This occurs due to an effect called regeneration. Regeneration is the process of

converting the kinetic energy contained by the centrifuge rotor back to potential energy

10


Supplement

stored In the capacitors in the Drive Control Module. During the regeneration process, the

motor in effect reverses roles and functions as a generator by converting mechanical energy

to electrical energy. Under most high operating speeds with various rotor loads, it is not

practical to store all of the regenerated energy returned back to the Drive. Therefore, the

energy must be consumed in some other fashion. This is accomplished by converting the

potential energy to heat energy.

The Drive uses a circuit called a shunt regulator to bum off this excess energy as heat.

This circuit consists of basically a transistor switch and a brake resistor (Calrod) acting

as a shunt. The brake resistor is located external to the drive within the centrifuge. To

consume the excess potential energy from the capacitors requires that the shunt resistor

be switched ON and OFF across the high voltage dc supply bus. Whenever the voltage rises

above a nominal 376 Vdc. the shunt is switched ON. As the voltage falls due to the loading

effect of the brake resistor, it is switched OFF at a nominal 366 Vdc. The brake resistor

has a nominal resistance between 10 and 12 ohms.

ac Input Current

When the Drive is initially powered up there will be a short power surge to charge the

internal high voltage power supply capacitors. This results in a peak current pulse during

power up of approximately 35 amps from the ac supply line during the first few ac line

cycles. This pulse may be noted to exponentially decay over four or five complete cycles

of the ac line power. These capacitors should be fully charged with the Drive ready to run

in less than five seconds after initial ac power is applied.

When accelerating the largest rotors, peak ac current sourced to the drive may reach 45

amps, with an RMS equivalent up to 20 amps. Because the dc power used within the Drive

is derived from full wave rectified ac off the line, ac current sourced into the Drive tends

to appear like a clipped sinusoid. This waveshape is referred to as a haversine. The

haversine current conduction angle will vary as a percentage of the total ac line voltage

waveform, and the peak of this haversine current will rise and fall as the centrifuge load

profile changes. In general, the higher the power demand by the centrifuge, the larger the

haversine current pulse.

Motor Current Control

The Drive senses motor current delivery through two contactless Hall effect current

sensors. These devices are conditioned through internal circuitry inside the drive to

provide an average current balance of within 5%, phase to phase, over the delivery range

of 250 milliamperes to 20 amperes.

The average output current delivered to the motor is commanded by the control console.

It has the ability to resolve this control signal, passed to the Drive by way of the REF PWM'"

interface pin, to 1 part out of 1024. This means that, in theory, it can command average

current In increments of 20 milliamperes. In actual practice, the motor needs a minimum

of 250 milliamperes to effect some rotation.

Actual average current control accuracy is approximately ± 5% over the range of 250

milliamperes to 20 amperes. These figures of merit should be valid over the temperature

range of 10°C to 50°C.

11


Supplement

Internal Operating Temperatures

The Drive uses forced air cooling to maintain low operating temperatures within the

chassis for high reliability and long life. The overtemperature projection built into the

Drive consists of two independent temperature sensors. One sensbr is mounted on the

power transistor heatsirik used for the output bridge. The second sensor is mounted on

the Logic Interface P. C. Board. Both sensor signals are used to safely shutdown the drive

should operating temperatures become unreasonably high. The sensor on the heatsink

is set to trip at a nominal 88°C.

Under normal operating conditions, these sensors should never effect a shutdown. If,

however, the exhaust port for the air moving through the Drive should become blocked or

should the fan malfunction, internal temperatures may rise to a level causing an

overtemperature fault, which will cause a shutdown.

Normal heatsink temperature should be below 84°C when the combined conditions of both

high ambient air temperature and high power delivery to the motor occur.

Acoustical Noise

The Drive is designed to operate quietly- However, when operating at high power levels.

such as during high acceleration rates and high braking rates, some acoustical noise may

be heard. The audibility of this noise may produce a buzzing sound to the listener when

the side cabinet panels are off the centrifuge. This is normal and Is caused by the

magnetostriction effects of the magnetics within the Drive.


Supplement

• small enclosure openings to limit finger access;

• printed circuit board trace spacings of at least 0.095 mm to ensure good over

surface insulation; and

• line side insulation sufficient to withstand 1500 volt.

Since the autotransformer is the main heat source, it is mounted outside the enclosure

and spaced away with mounting nuts (used as spacers). It radiates to the lower deck air,

minimizing the heating of internal enclosure components.

The heating and cooling solenoids are highly inductive. SP2210 relays are used to handle

such a low power factor load.

A special safety feature is the drive power presence sensing. A schmidt trigger optoisolator

is used to sense the presence of drive motor power, selected by relay K8, and convert to

a logic level square wave for transmission back to the controller. The controller then knows

that K8 is functional - tested at software startup in case of safety shutdown should the

drive not respond to a logic level OFF command in forward or should braking be stuck on

in the braking mode. This function gives a testable drive power shutdown to software

should logic level commands be Inoperative.

Because the optoisolator output is connected to the input of a nonmaskable processor

interrupt, there is uncertainty at startup. A schmidt trigger gate is used to inhibit the

compressor and drive motor feed power relays at power up. A few second delay ensures

that these outputs stay off. With drive feed off, the power present sensing is off, holding

the Interrupt line off, allowing the processor to complete its startup sequence.

TO CONTROLLER

P.C. BOARD

POWER

CONTROL

[^

1

20

3

16

5

7

9

11

13

15

17

19

J31

1

2

3

4

5

6

7

8

DRIVE CONTROL'

nc

VAC REL'

. LED SUPPLY

VAC ON-

LOCK DOOR-

COMPRESSOR ON-

HEAT'

. COOL'

. VACUUM BALLAST-

DRIVE MOTOR'

. OVREF

DRIVE POWER RETURN

DRIVE CONTROL FEED

nc(key)

DRIVE MOTOR FEED /

PROCESSOR P.S. FEED

PROCESSOR P.S. RETURN

COMPRESSOR FEED

. COMPRESSOR RETURN

POWER

DISTRIBUTION

BOX

["J30] HVacIN NEUTRAL /".

A0^

B0^ \>*

[JH] VAC/H.G. BYPASS ,,

\ i "c

^a 3 .24 V-/^

acRETURN „.'

VACUUM BALLAST ^'

COOL SOLENOID -

HEAT SOLENOID )

MOTOR FAN/DRIVE )

VACUUM REL SOL. /

DOOR LOCK ),, \ la


Figure 4. Power Distribution Box Input/Output

13


Supplement


e. Electronic System Glossary

Refer to Table 3 (below) In place of Table 3-6 (in Section 3 of the Service Manual).

Table 3. Electronic System Glossary

Code Origin Description

ABMINSPD

ACMON*

AIR TEMP IN

Drive Control Module

J33-7

U42-8 Controller P. C.

Board

Air Temperature

Sensor

AIR TEMP OUT U8-15 Controller P.C.

Board

AIR TEMP SEL U23-16 Controller

P. C. Board

BRAKE ENABLE* Drive Control Module

J33-11

BRIDGE

ENABLED*

CAUB*


J33-3

U15-12HostP. C.

Board

COMPRESSOR U52-9 Controller

ON* P. C. Board

COOL* U52-5 Controller

P. C. Board

DVEnab*/HOST U7-16 Host P. C.

ENABLE* Board

ABOVE MINIMUM SPEED. Back

EMF-derived independent tacho¬

meter check.

AC MONITOR. Tests the ac power

relay on the drive for proper opera¬

tion at start of every run.

AIR TEMPERATURE INPUT.

Input from air temperature sensor.

AIR TEMPERATURE OUTPUT. Scan

signal from computer to read air

temperature.

AIR TEMPERATURE SELECT Input

select to read data from air tempera¬

ture sensor.

Enables drive for braking action

(active low).

Drive control status back to Control¬

ler.

Calibrate command to URR

P. C. Board.

COMPRESSOR ON. Energizes

solid state relay which provides

208 Vac to compressor.

COOL. Energizes solid state relay

K4 to energize cooling solenoid.

Independent Host drive enable signal

so either Host or Controller can over¬

ride the other and shut drive down.

Denab* U7-12 Host P. C. Board LCID display enable signal.

'The asterisk indicates this is a NOT (active low) signal. (CONTINUED)

14


Supplement


Table 3. Electronic System Glossary (continued)


DIR

DOOR CLOSED

DOOR LOCKED

DOOR OPEN

DOOR

SOLENOID

DOWN*

DRIVER-

DRIVE AC

ENABLE

DXHOME

EOTV*

EXTERNAL

POWER +5VDC

EXTERNAL

COMMON

FORWARD

ENABLE*

FORWARD

ENABLE

POWER

U8-4 URR P. C.

Board

Microswitch on door

stop

Hall effect switch on

latch

Microswitch on door

stop

K3-1

U15-4URRP. C.

Board

U52-18 Controller

P. C. Board

Power Distribution

Box,J2-l

U6-8 Host P. C.

Board

U21-4 URR P. C.

Board


J-33, Pins 2. 8, 10.

12. and 16


J-33, Pins 4. 18 and 20


J33-5


J33-6

Signal advising Host direction of

door movement.

Door closed signal.

DOOR IS LOCKED. Door is fully

closed and door solenoid has de-

energized to lock door.

DOOR IS OPEN. Door has opened

far enough to trip door open switch.

DOOR SOLENOID, dc return for

door solenoid.

Down count from door position

system.

DRIVE POWER ENABLE. Energizes

solid state relay which supplies Drive

Control Module with 208 V.

Enables ac to the Drive Control

Module.

DOOR IS IN HOME POSITION.

When door is fully open. this

signal is high.

Pulse from URR advising that

URR data is complete and can

be processed for recognition.

+5 volt supply to Drive optoisola-

tors.

Ground return for Drive optoisola-

tors.

Enables drive for forward motion.

Separate power for forward command

optoisolator.

'The asterisk indicates this is a NOT (active low) signal. (CONTINUED) -1

15


Supplement




FULL CHOP*

HEAT*

HGBV^l

HGBV#2

IDEnab*

IDGate*

IMBALANCE

InitCt*

InitG*

JMPR SEL

JMPRTEMP

OUT

Jumper TEMP

SEL

LCDE


J33-9

U52-7 Controller

P. C. Board

K4-1

K5-1

U 15-10 Host P. C.

Board

U22-4URRP.C.

Board

Imbalance Detector

Ul 1-8 Host P. C.

Board

U9-4 URR P.C.

Board

U23-18 Controller

P. C. Board

U8-6 Controller

P. C. Board

U6-17 Controller

P. C. Board

U10-4 Host P. C.

Board

HALF OR FULL CHOP. Half chop

during normal acceleration and run;

full chop for rate control to MOSFET

drivers.

HEAT. Energizes solid state relay

K5 to energize hot gas solenoid.

HOT GAS BYPASS VALVE # 1. dc

return for hot gas valve #1.

HOT GAS BYPASS VALVE #2. dc

return for hot gas valve #2.

Signal advising URR Board that

initial count is complete and to now

count shaft encoder pulses.

Range pulse. Pulse width tells Host

result of the ultrasonic interrogation.

Imbalanced rotor.

Pulses to URR to calibrate X position

to center interrogate map over rotor

and drive.

First up count after door leaves

DxHome switch toggles this line.

telling Host it is time to send X offset

initial count pulses.

JUMPER TEMPERATURE SELECT.

Input select to read data from

jumper temperature sensor.

JUMPER TEMPERATURE OUTPUT.

Scan pulse from computer to read

juniper temperature.

Selects Jumper temperature

sensor.

Chip select signal for the 2 x 40

LCD display module.

"The asterisk indicates this is a NOT (active low) signal. (CONTINUED)

16


Supplement



LDEN*

LOCK DOOR*

U24-13 ControUer

P. C. Board

U52-12 ControUer

P. C. Board

MOTOR TEMP+ Drive Control Module

J33-13

MOTOR TEMP- Drive Control Module

J33-14

PROMOUT O*

PROMOUTI*

REFFWM*

SHUNT ACTIVE

Step*

SUP*

TACH INPUT

UP*

VAC ON*

VAC PUMP*

U25-11URRP. C.

Board

U25-12URRP. C.

Board

U38-16 ControUer

P. C. Board


J33-15

U12-4URRP.C.

Board

U27F-12URRP.C.

Board


J33-19

U14B-4URRP. C.

Board

U52-14 ControUer

P. C. Board

Kl-1

'The asterisk indicates this is a NOT (active low) signal.

LOAD ENABLE. Allows loading new

divisor in tachometer count chain.

LOCK DOOR Energizes solid state

relay K3 to energize rotary door

solenoid.

MOTOR TEMPERATURE INPUT.

Input voltage from motor tempera¬

ture sensor.

MOTOR TEMPERATURE OUTPUT.

Return path for voltage from motor

temperature sensor.

Interrogate trigger to range measure¬

ment circuits.

Initiates EOTV* signal when door

almost closed.

Reference pulse width modulated

motor current demand to Drive

Control Module.

Indicates brake activity.

Signal advising Host that door has

reached a URR interrogation point.

SWITCHED UP COUNT. Sometimes

carries Initial count; sometimes up

count from door position system.

Tachometer input from motor.

Up count from door position

system.

Energizes relay Kl to turn on vacuum

pump and hot gas bypass solenoid.

VACUUM PUMP. ac return for

vacuum pump motor and hot gas by¬

pass solenoid.

(CONTINUED) -'

17


Supplement



Code

VAC REL*

VAC SOLENOID

VACUUM

BALLAST-

VACUUM

LEVEL

WBG

WBG-TST-

HIGH

WBG-TEST-

LOW

WDOG

STROBE

Origin

U52-16ControUer

P. C. Board

K2-1

U52-3 ControUer

P. C. Board

Vacuum Sensor

P. C. Board

Q7 ControUer

P. C. Board

U24-16 ControUer

P. C. Board

U24-15 ControUer

P. C. Board

U47-19 ControUer

P. C. Board

Description

VAC RELEASE ENABLE. Energizes

solid state relay K2 to open vacuum

release solenoid.

Vacuum solenoid dc return for

vacuum solenoid.

Signal to activate vacuum

baUast.

Vacuum level input voltage

(0 to 1 volt fuU scale).

Emergency shutdown signal.

Signal for automatic test of

emergency shutdown circuit.

Signal for automatic test of

emergency shutdown circuit.

Watchdog strobe.

•The asterisk indicates this is a NOT (active low) signal.

Part 4: Repair and Replacement

a/ways wdiit,]pEwrm»iM^^^

a;re^ch


Supplement

a. Relay Printed Circuit Board Replacement

NOTE

Use this procedure in place of the procedure in the Service Manual, Section

4, paragraph 4-8.

CAUTION

Read paragraph 4-1 (Service Manual, Section 4), Precautions for Proper

Handling of Printed Circuit Boards, before you begin this procedure.

Paragraph 4*1 contains important information regarding how to prevent

injury and/or damage to printed circuit board components.

Replace the Relay P. C. Board (PN 59745):

1. Turn the centrifuge power OFF, and unplug the power cord.

2. Remove the centrifuge front and right-side cabinet panels.


4. Remove the Power Distribution Box mounting screw from the rear of the box, and


5. Turn the 1/4-turn fastener on the right side of the Power Distribution Box coun¬

terclockwise, and remove the panel from the box.

6. Disconnect plug P6 from the Relay P. C. Board.

7. Remove the Relay P. C. Board from inside the Power Distribution Box: push the tab

on the four fasteners (one in each comer of the board), and carefully pull the board

off the fasteners.

8. Position the new board inside the Power Distribution Box, connector side first - the

connectors go through the slot inside the box.

9. Push the board onto the four comer fasteners to secure the board in place.

10. Plug P6 into the Relay P. C. Board

11. Reinstall the panel on the Power Distribution Box. Turn the 1 /4-tum fastener on the

side of the box clockwise to secure the panel in place.

12. Reinstall the Power Distribution Box in the centrifuge, and secure it in place using the

screw removed in Step 4.


14. Reinstall the front and right-side cabinet panels.

19


Supplement

b. Circuit Breaker/Fuse Switch Replacement

NOTE


4, paragraph 4-11.

There are two circuit breakers (drive and compressor) and three fuse switches located

inside the Power Distribution Box (see Part 8, figure 66). Both circuit breakers are PN

90551, and all three fuse switches are PN 90565. Replace as follows:

1. Remove and disassemble the Power Distribution Box (see procedure a. Relay P. C.

Board Replacement. Steps 1 through 5).

2. Remove the Relay P. C. Board mounting plate (with Relay Board) by removing the three

screws that are holding it in place. Carefully place the plate and board assembly aside

so it will be out of the way for the remainder of the procedure.

3. Disconnect the wires from the circuit breaker or fuse switch being replaced. Make a

note of their orientation for reassembly.

4. Remove the circuit breaker or fuse switch:

• circuit breaker: remove the two screws from the outside of that box that hold the

breaker in place and remove the breaker;

• fuse switch: unscrew the fuse switch locking nut from outside the Power

Distribution Box and remove the switch; if the fuse is still good, remove it from

the switch and reinstall it in step 5.

5. Install new circuit breaker or fuse switch:

• circuit breaker: place the new breaker in position, and secure it in place using

the screws removed in Step 4.

• fuse switch: install the proper fuse in the fuse switch, then install the fuse switch

and tighten the locking nut to secure switch in place.

6. Reconnect all wires that were disconnected in Step 3.

7. Reassemble Power Distribution Box, reinstall it in the centrifuge and secure in place.



c. Solid State Relay (Drive & Compressor) Replacement

NOTE


4, paragraph 4-12.

20


Supplement

Two solid state relays (drive and compressor) are located inside the Power Distribution

Box; both relays are PN 69602. Refer to Part 8. figure 66 and replace the relay(s).

1. Remove and disassemble the Power Distribution Box (see procedure a. Relay P. C.

Board Replacement. Steps 1 through 5).

2. Remove the Relay P. C. Board mounting plate (with Relay Board) by removing the three

screws that are holding it in place. Carefully place the plate and board assembly aside

so it will be out of the way for the remainder of the procedure.

3. Disconnect the wires from the relay being replaced. Make a note of their orientation

for reassembly (see label on side of relay).

4. Remove the two relay mounting nuts (with lockwasher and flatwasher). Remove relay.

5. Apply thermal compound to the bottom of the relay, then position the new relay in

place and secure it with the mounting nuts and washers removed in Step 4.

6. Reconnect all wires that were disconnected in Step 3.

7. Reassemble the Power Distribution Box. Reinstall the box in the centrifuge and secure

it in place.



d. Changing the Vacuum Pump Oil (RC-28S Only)

NOTE

The procedure to change the vacuum pump oil is the same as the one in the

Service Manual, Section 4, paragraph 4-33, except as noted below.

• Change Step 8 to read:

Cut the nylon cable tie securing the vacuum pump drain line to the wiring harness.

• Change Step 16 to read:

Position the tubing clamp in place on the drain line. Close the clamp and tighten it

securely to seal the drain line. Secure the vacuumpump drain line to the wiring harness

using the nylon cable tie supplied.

• Replace figure 4-28 with figure 5.

e. Drive Motor Replacement

NOTE


4, paragraph 4-35.

1. Turn the centrifuge power ON and open the chamber door.

21


Supplement


Figure 5. Parts Identification, Vacuum Pump Oil Change

22


Supplement

2. Turn the centrifuge power OFF and unplug the power cord.

lliBB^^^^^^^^^^^

lliniisjptt^

||oentnfuge,|||y^ four minutes centrifuge

^pOIBWl^

inside the Drive Control Module that store a significant amount of energy.

^Tliese^capaci^^

|Fk»w^titslft]^

jii^SultlJitt^Mri^

3. Remove the front and right side cabinet panels.

4. Insert a 4 nun Alien wrench in centerhole on top of tapered drive spindle and loosen

screw by turning it counterclockwise. Pull the drive spindle off the drive shaft.

5. Using a 3 mm Alien wrench, remove the four outermost screws from heat shield in

bottom of chamber. Then using a 2.5 mm Alien wrench, remove the other four screws

from around centerhole of heat shield. Remove heat shield and heat transfer gasket.

6. Lift temperature sensor assembly off the motor shaft and set it aside out of the way.

7. Using a thin screwdriver with long shaft, carefully pry the doughnut 0-ring from

around the motor.

8. Remove both halves of dampening ring from around the motor. If they don't come out

easily, use one of the heat shield screws: thread screw into tapped insert in dampening

ring; pull up on screw to remove ring. then remove screw from ring.

9. Reinstall the tapered drive spindle on the drive shaft.

CAUTION

The tapered spindle is used to pull the drive motor from the centrifuge so

be sure it is fastened tightly to drive shaft.


11. Remove the Power Distribution Box mounting screw from the rear of the box. and


12. Make swrefourrnirvutes have elapsed since the powerwas turned OFF. then disconnect

the following plugs- in the order listed-from the Drive Control Module: P32, P34. P33,

andP9.

13. Using a 5 mmAllen wrench, remove the four screws holding the Drive Control Module

in place. Remove the module from the centrifuge.

23


Supplement


TAPERED

SPINDLE

SPINDLE

SCREW

EVAPORATOR

SEAL 0-RING

EVAPORATOR

HOI-DOWN

RING

0-RING,

SENSOR

LEAD

DAMPING

RING

HEAT SHIELD

HEAT

TRANSFER

GASKET

EVAPORATOR

ASSEMBLY

DETECTOR

ADJUSTMENT

SCREW

LOCKWASHER

LARGE NUT

28 mm (1 1/8 in.)

Figure 6. Parts Location, Drive Motor Replacement

24


Supplement

14. Open Velcro® fastener in vinyl cover around motor fan housing: remove vinyl cover.

15. Remove the motor ground wire (with two lockwashers) from the base of the frame, left

of the motor housing.

16. Using a 28 mm (1-1/8 inch) wrench, remove the large nut (with lockwasher and

washer) from the threaded gimbal post.

17. Lift the motor out of the centrifuge. Carefully guide the cables through the motor

housing. Lay the motor on a clean work surface.

CAUTION

Do not drop motor; do not expose it to temperatures above 120°C; and do

not lay it near metal objects. The motor is highly magnetic and heat or metal

objects can damage it.

18. Insert a 4 mm Alien wrench in centerhole on top of tapered drive spindle and loosen


19. Remove the gimbal assembly from the old motor:

a. Using the spanner wrench (or a strap wrench), unscrew the gimbal (clockwise)

and slide it off threaded gimbal post.

b. Unscrew (counterclockwise) the threaded gimbal post from the motor and remove

it from the motor.

20. Apply a light coat of antigalling grease (PN 61556) to the threaded surfaces of the

gimbal assembly, then Install both pieces of the gimbal assembly on the new motor.

21. Place tapered spindle on new motor, and tighten the screw in centerhole to secure the

spindle to the drive shaft.

22. Hold new motor assembly over the opening in chamber and rotate it so that the magnet

on the side of the motor Is aligned with imbalance detector and the cables on bottom

of motor are aligned over holes in motor housing (see Service Manual, Section 4, figure

4-31). Carefully guide motor cables through motor housing and lower motor in place.

CAUTION

Be careful not to pinch any of the motor harness between the gimbal and

the motor housing.

23. Insert a 4 mm Alien wrench in centerhole on top of tapered drive spindle and loosen


24. Check the alignment to the Imbalance detector: reach through the imbalance detector

slot at the top rear of motor housing and pinch sides of the imbalance detector and

motor rib simultaneously — they are approximately the same width, therefore.

pinching them together will cause magnet to align perfectly with the detector.

25. Place the nut. lockwasher. and washer removed in Step 16 on the threaded gimbal

post. Tighten the nut to 68 N»m (50 ft. Ibs) to secure the motor to the motor housing.

25


Supplement

26. Reconnect the motor ground wire (with lockwashers).

27. Wrap the vinyl cover around the motor fan housing, being careful to keep the two

motor cables separated, and close the Velcro® fastener.

NOTE

Do not tie the ribbon cable to the motor wires. To do so will cause an

increase in inductive electrical noise to the control electronics, resulting in

intermittent faults.

28. Position the Drive Control Module in place and secure it in place using the screws

removed in Step 13.

29. Reconnect plugs to the Drive Control Module in order. P9, P33, P34, and P32.

30. Reinstall the Power Distribution Box in the centrifuge and secure it in place using the

screw removed in Step 11.


32. Push both halves of the dampening ring in place around the motor until they are

seated against motor.

33. Clean doughnut 0-rlng and apply alight coat of vacuum grease to it. Place 0-ring

around the drive.

34. Slide the temperature sensor assembly back on the motor shaft.

35. Position heat transfer gasket in place (if damaged, replace with a new one PN 59618),

then align the four holes near the centerhole of the heat shield with the four holes in

the temperature sensor. Secure heat shield to temperature sensor with the four

screws removed in Step 5.

36. Rotate the heat shield to align the four outer holes in the heat shield with the holes

in the evaporator holddown ring; make sure the heat transfer gasket does not

protrude. Secure heat shield in place with the other four screws removed in Step 5.

37. Clean the end of the drive shaft and the inner area of the tapered spindle with acetone

or alcohol.

CAUTION

The drive shaft and tapered spindle must be clean. If they are not clean,

slippage will occur between the drive shaft and the tapered spindle,

possibly damaging the shaft or the spindle, or both.

NOTE

Before installing drive spindle, apply two drops of Loctite® 222 or 242

adhesive to threads inside shaft; be very careful not to get LOCTITE on

surfaces outside of threaded area.

26


Supplement

38. Install tapered drive spindle. Make sure the spindle is fully seated on the shaft, then

tighten the screw in the top of the spindle to secure it to the drive shaft.

39. Reinstall the right-side and front cabinet panels.

40. Plug in the power cord and turn centrifuge power ON.

41. Perform all necessary calibrations; see Service Manual. Section 8, Table 8-3.

42. RC-28S only. Conduct a run with a SUPRAspeed9 rotor and monitor vacuum level

in DIAGNOSTICS (Screen 1, User-1. #1). Verify that centrifuge pulls a vacuum ^ 2

mbar. If a SUPRAspeed® rotor is not available, check vacuum level using DIAG¬

NOSTICS, Screen 3, Serv-2. #9 and follow display prompts.

43. Use highest speed rotor available that is intended for use in the centrifuge, and

conduct a test run to maximum speed of the rotor; verify that rotor reaches top speed.

f. Drive Motor Fan Replacement

The procedure to replace the drive motor fan is the same as the one in Section 4, paragraph

4-36 with the following exception: do not remove the Power Distribution Box; remove the

Drive Control Module instead.

g. Drive Control Module Replacement

Following is the replacement procedure for the new Drive Control Module, PN 59752:

1, Turn the centrifuge power OFF, and unplug the power cord.

IBIIBMi^^^^^^^^^

^^^

| Tliere^arech^^ the Drive Control Module that store a

significant amount of energy. These capacitors remain elertncally cner-?

gized for four minutes after the power is turned OFF. Failure to Wait four

'Imfiiuliiesl^canTesuft

2. Remove the front and both side cabinet panels from the centrifuge.

3. Make sure Jbw minutes have elapsed since the power was turned OFF. then disconnect

plugs, in the order listed, from the Drive Control Module: P32, P34. P33, and P9.

4. Using a 5 mm Alien wrench, remove the four screws holding the module in place.

Remove the module.

5. Position the new Drive Control Module in place and secure it in place using the screws

removed in Step 4.

6. Reconnect plugs to the Drive Control Module in order P9. P33. P34, and P32.

27


Supplement

NOTE

Do not tie the ribbon cable to the motor wires. To do so will cause an

increase in inductive electrical noise to the control electronics, resulting in

intermittent faults.

7. Reinstall all cabinet panels. Plug in the centrifuge power cord.

8. Perform all necessary calibrations; see Service Manual. Section 8. Table 8-3.

Part 5: Diagnostics &. Fault Troubleshooting

a. Screen 1, Fault Messages

NOTE

Four new fault messages have been added: Bad AC Power Relay, Bad Brake

Monitor Circuit, Bad Min Speed Monitor, and Calrod Overtemp (described

below). Flow charts for these faults are included in this supplement. In

addition, several flow charts from Section 5 of the Service Manual have

been revised for use with RC-28S centrifuges S/N 9002294 & above and

all RC-24 centrifuges; the revised flow charts are also included. See list of

new/revised flow charts below and on next page.

Following is a description of the four new fault messages:

Bad AC Power Relay. Refrigeration System fault that occurs if the ac power relay that

supplies power to the Drive Control Module is not working. See figure 7.

Bad Brake Monitor Circuit, Drive System fault. The PWM signal from the Calrod

shunt is multiplexed, filtered, then converted to a digital voltage. This fault occurs if

the voltage is not at the correct level. See figure 8.

Bad Min Speed Monitor. Drive System, Bridge fault. This fault checks for a failed

tachometer. ABMINSPD is active high when rotor speed if greater than 2000 rpm. and

it is active low when rotor speed is less than 1000 rpm. The fault occurs if tachometer

reads 0 rpm and rotor is coasting at a high speed. See figure 10.

Calrod Overtemperature. An Overspeed System fault that occurs when the brake

resistor heating element has the full 208 volts across it. If the braking FET shorts out,

it can place line voltage across the brake heating element (Calrod), causing it to get

extremely hot and present a fire hazard. See figure 12.

Following is a complete alphabetical list of the fault messages that have new or revised flow

charts (the flow charts are figure 7 through 53). If the fault message does not appear in

this list, use the flow chart in Section 5 of the Service Manual.

Bad AC Power Relay Calrod Overtemp Door Not Latched

Bad Brake Monitor Circuit Can't Reach Full Vacuum Door Not Locked

Bad Drive Accel Ctrlr Drive Enable Out Door Open Switch

Bad Min Speed Monitor Door Locked Switch Drive Enable (Ctrlr Off)

Bad Speed Control Door Not Closed Drive Enable ( H & C Off)

28


Drive Enable (Host Off)

Drive Failed to Start

Drive Still Enabled

Dv-Enab FALSE Refused

Dv-Enab TRUE Refused

High Chamber Temp

High Drive Temperature

Improbable Speed Chng

Inertia Out of Range

Inertia Too High

Inertia Too Low

Inoperable Vacuum

Instrument Overspeed

Loss of Tachometer

Low Chamber Temp

No Ctrlr Drive Disable

No Ctrlr Drive Enable

No Decel Detected

No Door Unlock

No Drive Enable (H & C)

Open Winding Sensor


Supplement

Rotor Overspeed

Rotor Overtemp

Shorted Winding Sensor

Speed Overshoot Trap

Temp Out of Range

Vacuum Loss

Vacuum Release Failure

Warn-Marginal Vacuum

Warning-Hot Gas Failed

Warning-Low Accel

Warning Poor Brake

b. Screen 2, User DIAGNOSTICS

The following changes have been made to Screen 2. User DIAGNOSTICS (refer to Service

Manual, Section 5, Table 5-2):

• User-1 routines #21 through #25 are no longer used

• User-1 #31 was changed from Bridge Current Sense (A) to Shunt Active Sense (see

description below)

31 Shunt Active Sense Type: Monitor

Monitors the filter output for SHUNT_ACTIVE. The range is from 0 to 5 volts, where

5 volts is normal. If reading is less than 0.5 volts, there is a short across the Calrod.

Should read 5 volts at all times except during braking with the brake ON, in which case

it should read from 3 to 5 volts. If reading indicates much less than 5 volts, there is

a problem and the Calrod Overtempeture fault will occur.

• Replace the description of User-1 # 32. HES Offset, with the following:

32 HES Offset Type: Monitor

The value displayed remains constant at 36; its onlypurposeis to indicate the current

HES Offset.

c. Screen 3, Service DIAGNOSTICS

The following change has been made to Screen 3, Service DIAGNOSTICS (refer to Service

Manual. Section 5. Table 5-9):

• Serv-2 #24 was changed from Temp Offset Coeff to Lock A/D on Shunt Active (see

description below)

24 Lock A/D on Shunt Active Type: Override

Causes the Controller P. C. Board to display only the SHUNT_ACTIVE input and to

ignore the other sensor inputs.

29/30

SORYALL® Centrifuges RC-28S/RC-24 Service Manual

Supplement

Catastrophic fault. Clears when centrifuge power is turned OFF.

Figure 7. Bad AC Power Relay

31/32


Supplement


Figwe8. Bad Brake Monitor Circuit

33


Supplement


FAULT: Bad Drive Accel

See figure 23 (FAULT:

Drive Failed to Start).

Nonrecoverable fault. Clears at zero setspeed.

Figure 9. Bad Drive Accel

34


Supplement


Figure 10. Bad Min Speed Monitor

35

R028S/RC-24 Service Manual

Supplement


FAULT: Bad Speed Control

See fig. 43 (FAULT:

Rotor Overspeed).


Figure 11. Bad Speed Control

36


Supplement

Catastrophic fault. Clears when centrifuge power is turned off.

Figure 12. Calrod Overtemp

Rev. 7/93 37


Supplement


FAULT: Cant Reach Full Vacuum

See figure 48

(FAULT: Vacuum Loss).

Nonrecoverable fault. Clears at start of next run.

Figure 13. Can't Reach Full Vacuum

38


Supplement

Nonrecoverable fault. Clears at zero setspecd.

Figure 14. Ctrlr Drive Enable Out

39/40


Supplement

Noairecoverable fault. Clears whesi switch configuration Is corrected.

Figure 15. Door Locked Switch

41/42


Supplement


Figure 16. Door Not Closed

43


Supplement



Figure 17. Door Not Latched

44

SORVALL®Centrifuges RC-28S/RC-24 Service Manual

Supplement

FAULT: Door Not Locked

See figure 17

(FAULT:Door Not

Latched).


Figure 18. Door Not Locked

45


Supplement


Nonrecovcrable fault. Clears when switch configuration is corrected.

Rgure 19. Door Open Switch

46


Supplement


Figure 20. Drive Enable (Ctrlr off)

47


Supplement


FAULT: Drive Enable (H & C off)

See figure 24

(FAULT: Drive Still

Enabled).


Figure 21. Drive Enable (H & C off)

48


Supplement

FAULT: Drive Enable (Host off)

Turn centrifuge power ON, but

do not start a run. See if DS-3

on the Host PCB is ON.


Figure 22. Drive Enable (Host off)

49/50

SORVALL® Centrifuges RC-28S/RC-24 Sendee Manual

SuppSemesit


Figure 23a. Drive Failed to Start

51/52

SORVALL® Centrifuges RC-28S/RC-24 Service Mamsal

Supplement

Nossrecoverable fault. Clears at start of next run.

Figure 23b. Drive Failed to Start

53/54


Supplement

Catastrophic fault. Clears when Host Reset and BRIDGE ENABLED* arc

cleared by the Controller P. C. Board (i.e., centrifuge power OFF).

Figure 24. Drive Still Enabled

55


Supplement


FAULT: Dv Enab FALSE Refused

^

Unplug P10 from Ctrir PCB. Check rbn cbl from P10

on Ctrir PCB to P33 on DCM for opens and/or shorts.


Figure 25. Du-Enab FALSE Refused

56


Supplement

FAULT: Dv Enab TRUE Refused


Dv Enab FALSE

Refused).


Figure 26. Dv-Enab TRUE Refused

57


Supplement


Recoverable fault. Clears when Controller P. C. Board measures air and

base temperature


Supplement

Recoverable fault. Clears when motor winding temperature is


Supplement


Catastrophic fault. Clears when Controller P.C. Board detects no brake,

no forward torque, and a speed of


Supplement

FAULT: Inertia Out of Range

See figure 31

(FAULT: Inertia

Too High).


Figure 30. Inertia Out of Range

61


Supplement



Figure 31. Inertia Too High

62


Supplement

FAULT: Inertia Too Low

See figure 31

(FAULT: Inertia

Too High).

Nonrccoverable fault. Clears at zero setspeed.

Figure 32. Inertia Too Low

63


Supplement


FAULT: Inoperable Vacuum


Vacuum Loss).

Nonrecovcrable fault. Clears when vacuum pump turns OFF.

Figure 33. Inoperable Vacuum

64


Supplement

Nonrecoverable fault. Clears at zero setspeedc

Figure 34. Instrument Ouerspeed

65/66


Supplement

Catastrophic fauSt. Clears when Controller P.C. Board detects no brake, no forward torque, and a speed of


Supplement

FAULT: Low Chamber Temp

Perform a run to 2000 rpm using any rotor

intended tor use in RC-28S. Go to DIAG

Screen 2, User-1 #2. Turn monitor ON.

When DIAG screen displays 4°C, watch

U45-4 & U45-5 on Ctrlr PCB.

Recoverable fault. Clears when air temperature is > -20°C.

Figure 36. Low Chamber Temp

69


Supplement


Check revision level of Host

PCB and Ctrir PCB to be

sure they are compatible.

Call Du Font for current

software information.

See fig. 24

FAULT: Drive

Still Enabled. •YES

Nonrecoverable fault. Clears at start of next run,

Figure 37. No Ctrlr Drive Disable

70


Supplement


Figure 38. No Ctrlr Drive Enable

71


Supplement


FAULT: No Decel Detected

Perform a run to 10 000 rpm

with Brake On. Press STOP and

watch U40-2 & U40-8 on Ctrlr

PCB. They should be OFF as

long as speed is >2000 rpm.

YES

Restart run. At set speed (10K),

press STOP and unplug P10

from Ctrlr PCB. Watch U40-2

& U40-8. They should be OFF

as long as speed is >2000 rpm.


Figure39. No Decel Detected

72


Supplement

Nosirecoverable fault. Clears at start of next run.

S^ure 40. No Door Unlock

73/74

SORYALL® Centrifuges RC-28S/RC-24 Service Manual

Supplement

Nonrccoverable fault. Clears at start of next run.

Rev. 7/93

Figure 41. No Drive Enable (H & C)

75/76


Supplement

FAULT: Open Winding Sensor

Check J21 on the Ctrir PCB.

Pins must be properly oriented

and there should be a jumper

across top 2 pins (PI & P16).

Install J21 so pins are properly

oriented. If top pins are not

jumpered, remove J21, rotate

it 180° and reinstall it.

Nonrecoverable fault. Clears when chamber door is opened.

Figure 42. Open Winding Sensor

77


Supplement



Figure 43. Rotor Ouerspeed

78


Supplement

FAULT: Rotor Overtemperature - Troubleshooting Procedure:

IMPORTANT: Before beginning to troubleshoot, note if the fault occurred during a

vacuum run. If so, when checking to see if fault reoccurs, first perform a pull-down run

at maximum air speed. If fault reoccurs, continue to troubleshoot. If fault does not

reoccur, perform a pull-down run at maximum vacuum speed. If fault reoccurs during

the vacuum run, troubleshoot the vacuum system.

Go To

Step Required Action & Evaluation Conclusion Step

1 Precool/preheat rotor in centrifuge being sure to reenter (rekey) desired Temp

and accept the Max default. Press START, go to D1AG, Screen 2, User-1, #2

and turn Monitor ON. Ctrlr Sample Temp should be within 2° of Set Temp in

30 minutes or less. Do temperatures equalize within 30 minutes? yes 2

no 3

2 Does fault reoccur? yes 3

no END

3 Visually check condenser. Is inlet blocked? yes 4

no 5

4 Clean condenser/clear blockage. Does fault reoccur? yes 5

no END

5 Perform A/D Channel 0 Check (Section 6, para. 6-2), and check Air and Jumper

Sensors using the Temperature Sensor Verification Check (Section 6, fig. 6-10).

Replace any faulty sensor. Does fault reoccur? yes 6

no END

6 Is REFRIGERATION CB (CB2) on PDB tripped? yes 7

no 13

7 Reset CB2 and perform a run @ 2000 rpm and-20°C. Does CB2 trip again? yes 8

no END

8 Press STOP and turn power OFF. Unplug P/J101 at compressor. Connect DMM

(set at lOOOVac scale) to J101-1 & J101-2. Turn power ON, restart run and check

DMM. Voltage (±10%) should be 230V for 60Hz, or 190-200V for 50Hz.

Is voltage correct? yes 10

no 9

Recoverable fault. Clears at start of next run or when START is pressed.

Figure 44. Rotor Overtemperature

79


Supplement


Go To

Step Required Action & Evaluation Conclusion Step

9 Correct wiring at TB1 inside PDB as explained in Voltage Conversion (para. 2-3),

then restart run. Does CB2 trip again? yes 10

no END

10 Press STOP and reset CB2. Reconnect P/J101 (if not already reconnected) and

place DMM clamp-on device on one of the compressor wires. Set DMM for ac

amps and restart run. Is current 5A? yes

no

14 Visually check condenser fan. Is fan operating?

15 Check fan wiring, repair or replace fan as required. Does fault reoccur?

16 Check HEAT LED on PDB. Is it ON?

17 Charge Refrigeration System.

18 Check U45-5 on Ctrlr PCB. Is it ON?

19 Replace Relay PCB.

20 Press STOP and turn power OFF. Unplug P9 from Ctrlr PCB and turn power

back ON. Go to DIAG Screen 3, Serv-2 #3. Turn (Ovride) ON, press on/off

to de-energize Hot Gas Control Solenoid (HGBV 2). Did U45-5 go OFF?

21 Replace Ctrlr PCB.

22 Reconnect P9 to Crtir PCB, and unplug P2 from PDB. Is U45-5 still OFF?

yes

no

yes

no

yes

no

yes

no

yes

no

yes

no

11

12

END

END

14

24

16

15

16

END

18

38

END

20

19

END

22

21

END

19

23

Figure 44. Rotor Overtemperature (continued)

80


Supplement

Step Required Action & Evaluation

23 Replace rbn cbl from Ctrlr PCB (P/J9) to PDB (P/J2).

24 Check RFG CMPR LED on PDB. Is it ON?

25 Check for HVac at compressor connector P/J101. Is there high voltage?

26 Open between J101 at compressor and P31 -7/P31 -8 at PDB. Repair harness.

27 Check Cap Box. Is Cap Box OK?

28 Compressor problem. Replace compressor.

29 Check Overload Relay on top of compressor for continuity. Is there continuity?

30 An overload condition occurs at very high temperatures. Is compressor hot?

31 Replace Overload Relay. Does compressor turn ON?


33 Press STOP and turn power OFF. Unplug P9 from Ctrlr PCB and turn power

back ON. Go to DIAG Screen 3, Serv-2 #2. Turn (Ovride) ON, press on/off

to energize compressor. Did U45-6 come ON?

34 Reconnect P9 to Crtir PCB, and unplug P2 from PDB. Is U45-6 still ON?

35 Press STOP and turn power OFF. Temporarily replace rbn cbl from Ctrlr PCB

(P9) to PDB (P2) and reconnect DMM clamp-on device on a compressor wire.

Turn power ON and Press START. After 15 seconds, is current >5A?

Go To

Conclusion Step

END

yes 25

no 32

yes

no

yes

no

yes

no

yes

no

yes

no

yes

no

yes

no

yes

no

yes

no

29

26

END

28

12

END

27

30

28

31

END

27

35

33

34

21

19

23

23

36

Figure 44. Rotor Ouertemperature (continued)

81


Supplement


Step Required Action & Evaluation

Go To

Conclusion Step

36 Press STOP and turn power OFF. Reconnect original rbn cbl and check continuity

across the compressor signal path on Relay PCB. Continuity check OK? yes 37

no 19

37 Replace Compressor Relay inside PDB.

38 Check COOL LED in PDB. Is it ON?


END

yes 39

no 42

yes 40

no

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