Teledyne 4700 Serivce Manual
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Teledyne 4700 Serivce Manual

Refrigerated sampler
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4700 Refrigerated
Sampler

Service Guide

Part #69-4703-093 of Assembly 60-4704-059
Copyright © 2008. All rights reserved, Teledyne Isco, Inc.
Revision F, October 20, 2010.

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Summary of Contents for Teledyne 4700

  • Page 1: Service Guide

    4700 Refrigerated Sampler Service Guide Part #69-4703-093 of Assembly 60-4704-059 Copyright © 2008. All rights reserved, Teledyne Isco, Inc. Revision F, October 20, 2010.
  • Page 3 Isco 4700 Refrigerated Sampler Service Guide Safety Safety Information The Isco 4700 Refrigerated Sampler is a “definite purpose” device, intended for use only with compatible Isco equipment. Except as described in this manual, do not use this product with any other manufacturers’ equipment, or for any other purpose.
  • Page 4 Isco 4700 Refrigerated Sampler Service Guide Safety General Warnings Before installing, operating, or maintaining this equipment, it is imperative that all hazards and preventive measures are fully understood. While specific hazards may vary according to location and application, take heed in the following general...
  • Page 5 Isco 4700 Refrigerated Sampler Service Guide Safety The equipment and this manual use symbols used to warn of Hazard Symbols hazards. The symbols are explained below. Hazard Symbols Warnings and Cautions The exclamation point within the triangle is a warning sign alerting you of important instructions in the instrument’s technical reference manual.
  • Page 6 Isco 4700 Refrigerated Sampler Service Guide Safety...

  • Page 7: Table Of Contents

    4700 Refrigerated Sampler Service Guide Table of Contents Section 1 Introduction and General Guidelines 1.1 About this Manual........... 1-1 1.2 Technical Specifications .
  • Page 8 4.1 4700 CPU Circuit Board Description ........
  • Page 9 1-4 Wetted parts ............1-10 1-5 4700 Sampler to RS-232 serial communication cable ..... 1-11 1-6 Self-tapping screws: reinstallation .
  • Page 10 4700 Refrigerated Sampler Service Guide Table of Contents 2-6 Opening the pump housing cover and latch ......2-6 2-7 Top cover bushing .
  • Page 11 2-2 Distributor Parts List ..........2-29 3-1 Replacement Parts for 4700 Refrigerator ....... . 3-1 3-2 Refrigeration System Troubleshooting .
  • Page 12 4700 Refrigerated Sampler Service Guide Table of Contents...

  • Page 13: Section 1 Introduction And General Guidelines

    Service Guide Section 1 Introduction and General Guidelines 1.1 About this Manual This manual contains servicing information for the model 4700 indoor/outdoor refrigerated sampler. The manual contains four sections and three appendices. Section 1, Introduction and General Guidelines, contains safety Teledyne Isco, Inc.

  • Page 14: Technical Specifications

    4700 Refrigerated Sampler Service Guide Section 1 Introduction and General Guidelines 1.2 Technical Table 1-1 contains technical specifications for the 4700 sampler. Specifications Table 1-1 4700 Technical Specifications 130  72  84 cm 51  28  33 in Size (HWD):...
  • Page 15 4700 Refrigerated Sampler Service Guide Section 1 Introduction and General Guidelines Table 1-1 4700 Technical Specifications (Continued) Speed: Approx. 300 RPM, depending on sampling conditions Liquid Presence Detector: Non-wetted, non-conductive sensor detects when liquid sample reaches the pump to automatically compensate for changes in head heights.

  • Page 16: Connection To Other Devices

    1.3 Connection to Other Table 1-2 lists the pin functions of the sampler’s rear connector, for connection to external devices. Devices Figure 1-1 16-pin rear connector Table 1-2 4700 Connector Pin Functions Sampler Pin Signal Name Input/Output Parameters/Comments 12 VDC Power Output +12.5 VDC, 1 ampere maximum.

  • Page 17: General Maintenance

    1.4 General Maintenance The following sections describe general inspection and mainte- nance tasks to be performed on the 4700. 1.4.1 Pump Inspect the pump before each use. Inspections are especially important when pumping large sample volumes over long dis- tances or when the sample liquid contains a high percentage of suspended or abrasive solids.
  • Page 18 4700 Refrigerated Sampler Service Guide Section 1 Introduction and General Guidelines Figure 1-2 4700 Pump Pump Tube Liquid Detector Cover Bulkhead Fitting Latch Tubing Coupler Knob Alignment Notches Pump Housing Alignment Collars Pump Housing Band CAUTION This sampler has a high performance pump. As with all such pumps, it relies upon liquid to cool working components.

  • Page 19: Pump Tube Replacement

    4700 Refrigerated Sampler Service Guide Section 1 Introduction and General Guidelines Figure 1-3 Rollers (A) and guides (B) on the pump rotor b. Pump Rotor – Look for debris buildup on the pump roller or guide surfaces (Figure 1-3). Clean when needed (Section 1.4.3).
  • Page 20 4700 Refrigerated Sampler Service Guide Section 1 Introduction and General Guidelines 2. Loosen the Liquid Detector Cover (G) by unscrewing the large black knob (I). 3. Unlatch the Pump Housing Band (K). 4. Pull the tube (A) away from the bulkhead fitting (B) and disconnect the tubing coupler and suction line.

  • Page 21: Cleaning The Pump Rollers

    4700 Refrigerated Sampler Service Guide Section 1 Introduction and General Guidelines Example: Resetting the Pump Tube Alarm 1. From the Main Menu screen select CONFIGURE. 5. You can modify the pump tube alarm setting to tailor it to your needs. The factory default setting is...

  • Page 22: Refrigerator Cleaning Guidelines

    4700 Refrigerated Sampler Service Guide Section 1 Introduction and General Guidelines For application-specific requirements, consult with your labo- ratory to establish cleaning or replacement protocols. Figure 1-4 Wetted parts Strainer (316 stainless steel, Bulkhead Fitting (316 stain- polypropylene, or CPVC)

  • Page 23: Software

    This zipped file contains two files: the 4700 software .bin file and a .pdf file documenting the history of all 4700 soft- ware updates to the present. Extract these two files. 3. With the 4700 turned on, connect it to your computer.

  • Page 24: System Ids

    4700 Refrigerated Sampler Service Guide Section 1 Introduction and General Guidelines CAUTION This procedure will cause most programmed entries and accu- mulated data stored in the sampler to be lost, and the sampler will revert to factory default settings. If this operation is per- formed, it will be necessary for you to reprogram the unit to meet the specifications of your installation.

  • Page 25: Safety Precautions

    4700 Refrigerated Sampler Service Guide Section 1 Introduction and General Guidelines 1.6 Safety Precautions There are several precautions you should observe before attempting to remove and replace a module: WARNING Removing a module exposes you to electrical and mechanical hazards. Always disconnect from AC power before attempting to remove any module.

  • Page 26: Major Assembly Removal And Replacement

    4700 Refrigerated Sampler Service Guide Section 1 Introduction and General Guidelines 1.7 Major Assembly Teledyne Isco designed the sampler for easy field replacement of its sub-assemblies. This expedites the repair and saves shipping Removal and costs. These sub-assembly modules should be replaced by trained Replacement personnel.

  • Page 27: Accessing The Rear Components

    Section 1 Introduction and General Guidelines Wait for click Figure 1-6 Self-tapping screws: reinstallation 1.8 Accessing the Rear 1. Disconnect the 4700 from AC power. Components WARNING Removing the refrigeration module exposes you to electrical and mechanical hazards. Always disconnect from AC power before exposing the refrigeration module.

  • Page 28: Closing The Rear Compartment

    4700 Refrigerated Sampler Service Guide Section 1 Introduction and General Guidelines Refrigeration module Insulation Turn module panel out and left Back cover Cover brace Adhesive strip Figure 1-7 Remove back cover and insulation, refrigeration module 1.9 Closing the Rear Ensure that the control wiring runs through the notches in the plastic refrigerator body.

  • Page 29: Rear View With Module Removed (Adhesive Strips, Permagum Sealant, Power Cables)

    4700 Refrigerated Sampler Service Guide Section 1 Introduction and General Guidelines Permagum sealant Adhesive strips Power supply cables Figure 1-8 Rear view with module removed (Adhesive strips, Permagum sealant, power cables) Adhesive Center strip screw Permagum sealant Figure 1-9 Rear view of refrigeration module (Adhesive strip, Permagum sealant) Replace the refrigeration module, insulation, rear panel, and cover brace, reversing the steps in Section 1.8.
  • Page 30 4700 Refrigerated Sampler Service Guide Section 1 Introduction and General Guidelines 1-18...

  • Page 31: Section 2 Sample Delivery System

    Hidden menu tests are listed in Section 5.2. Test points For a complete list of 4700 test points and values, refer to Section 4.2. Test points are also highlighted in red on the CPU schematic in Figure A-5, Appendix A.

  • Page 32: Pump Module Replacement

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2.2 Pump Module The pump module is replaceable as a single unit. There have been updates to the 4700 pump. See Section 2.3.5 for detailed Replacement information about pump versions. 60-4704-128 (new)

  • Page 33: Pump Module Replacement

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 7. Align the module over the mounting holes and secure it with the mounting screws, inserting the top three first. 8. After all six screws are inserted, tighten and torque to 16 to 18 in/lbs.

  • Page 34: Pump Disassembly And Parts Replacement

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Note When the hinged portion of the pump module is opened, another large screw is revealed (Figure 2-4). This is a sealed port used solely for factory testing. Do not loosen or remove this screw.
  • Page 35 4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Table 2-1 Pump Parts List (Continued) Optical sensor wiring assembly 69-4704-025 Hold-down kit for detector barrier 68-4700-037 Pump base with detector 68-4704-039 Pump cover installation kit 68-4700-101 Pump heater kit 120 VAC...

  • Page 36: Thumb Screw

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2.3.2 Thumb Screw If removal of the thumb screw is necessary, first unscrew the thumb screw and lift the hinged half of the pump cover. Pry the o-ring loose with a small flat screwdriver and then pull the shaft out of the pump cover.

  • Page 37: Top Cover Bushing

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Tighten the screws to 20 - 28 in/lbs. Plastic bushing To remove the black plastic bushing in the cover, push it out with your thumb from the top (Figure 2-7). When replacing this bushing, align the key in the bushing with the groove in the cover (Figure 2-6).

  • Page 38: Optical Disk & Sensor

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Latch screws Figure 2-9 Pump band latch 2.3.4 Optical Disk & Sensor Removal of the optical disk may become necessary, either for replacement of the disk and sensor, or in order to free the drive shaft.

  • Page 39: Recent Changes To The Pump

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2.3.5 Recent Changes to the The old 4700 power supply has been replaced by a new, more Pump powerful power supply. The pump assembly has been redesigned to take advantage of this feature, eliminating the need to "break in"...

  • Page 40: Old And New Mounting Plate (Idler Gear On Opposite Side)

    Section 2 Sample Delivery System The idler bushing is now installed in the middle left hole in the motor mount plate (Figure 2-11). Older 4700 pump modules have the idler gear installed on the other side of the chamber. Corre- spondingly, the idler bushing is located in the middle right hole in the plate.

  • Page 41: Pump Motor And Wiring

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2.3.6 Pump Motor and 1. Free the motor from the module’s wiring by cutting the Wiring plastic cable tie. 2. Remove the nut and optical disk from the pump shaft.

  • Page 42: Motor Replacement

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2.3.7 Motor Replacement When installing the motor and plate assembly, attach the plate to the base using the original four holes to insert the mounting screws (see Figures 2-13 and 2-15). The unused holes should only be used if the original threaded holes are damaged.

  • Page 43: Rotor

    CAUTION If the ferrite bead is not positioned as shown in Figure 2-16, the pump module will not fit into the 4700 cabinet properly, as shown in Figure 2-3 on page 2-3, resulting in the gasket not sealing when the pump module is attached to the cabinet.

  • Page 44: Gasket

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2.3.9 Gasket Replace the gasket using the following steps, as shown in Figure 2-18. 1. Always begin by pressing the gasket into one corner of the base. 2. Pull the gasket taut, then press the gasket down into the opposite corner.

  • Page 45: Detector Protective Barrier

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Figure 2-19 Improper installation of the gasket 2.3.10 Detector Protective The liquid detector’s protective fluoroglass barrier (Figure 2-20) Barrier can be removed for cleaning or replacement. It is anchored by a hold-down panel on either side.

  • Page 46: Pump Cover Assembly

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Tubing grooves (keep clean) Remove hold-down panels (2) Peel up fluoroglass barrier Apply silicone sealant Piezo film detector Figure 2-20 Removing the detector protective barrier 2.4 Pump Cover Assembly The pump cover assembly (Isco part #60-4704-142) was...

  • Page 47: Aligning The Cover

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Pump Cover Assembly Reference line Figure 2-21 Aligning the cover 3. Open the cover, holding the bottom edge along the refer- ence line, and positioning the cutout over the tubing bulk- head (Figure 2-22).

  • Page 48: Aligning The Latch Keeper

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Reference marks 3/16” (4.5 mm) Figure 2-23 Aligning the latch keeper 9. Realign the latch keeper and secure it in place with two self-tapping screws (Figure 2-24). Tighten until fully seated.

  • Page 49: Optional Heater

    Under extremely cold conditions, the optional pump heater pre- vents liquid from freezing inside the pump. Early model 4700 Refrigerated Samplers do not have the pump cover, a part that is required for this heater. Customers wishing to install a heater onto one of these early samplers can contact the factory to receive a pump cover at no charge.

  • Page 50: Install Heat Shield Inside Cover

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 13 mm Figure 2-25 Cut a notch in the top cover for the AC line cord 2. Fit the heat shield inside the pump cover as shown in Fig- ure 2-26. Secure the shield with the four #6...

  • Page 51: Install Heater Under Pump

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Figure 2-27 Install heater under pump 5. Secure the heater in place with the two #142" self-tap- ping screws. Tighten the screws until fully seated. 6. Refer to Figure 2-28 and secure the AC line cord just inside the notch in the cover, with the clip and the #8...

  • Page 52: Distributor

    This signal will be low when both phases are being driven at 70.7%. For a complete list of 4700 test points and values, refer to Section 4.2. Test points are also highlighted in red on the CPU schematic in Figure A-5, Appendix A.

  • Page 53: Distributor Module Replacement

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2.7 Distributor Module The distributor module can be replaced as a single unit. Replacement 68-4704-029 WARNING Risk of injury or equipment damage. Familiarize yourself with the general instructions in Sections 1.7 and 1.6 before proceeding.

  • Page 54: Disassembling The Distributor

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Figure 2-30 Distributor module removal 6. Clean the distributor module’s mounting surface inside the refrigerated compartment. This will help ensure that the gasket on the new module will seal to the enclosure.

  • Page 55: Removal Of Stepper Motor And Optical Sensor

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 3. Slide the stepper motor assembly slightly toward the dis- tributor shaft to disengage it from the timing belt and remove it. 4. Remove the two screws holding the optical sensor in place.

  • Page 56: Rebuilding The Distributor

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2.9 Rebuilding the This section details the replacement steps for each of the dis- tributor components. Distributor 2.9.1 Gasket Replace the gasket using the following steps, as shown in Figure 2-33.

  • Page 57: Distributor Shaft

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2.9.2 Distributor Shaft To assemble the distributor shaft, refer to Figure 2-34 and do the following: 1. Place the disk spacer on the bottom side (shaft side) of the shaft gear, aligning the four pairs of holes.

  • Page 58: Installing The Cover Plate

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Gaps Figure 2-35 Improperly positioned timing belt 2. Place the stepper motor on the chassis without tightening the mounting screws, ensuring that the belt is around the motor gear. 3. Place the cover plate on top of the shaft and reattach with the three large self-tapping screws.

  • Page 59: Optical Sensor

    4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System Press back Press & turn Press & turn Figure 2-37 Timing belt alignment 2.9.4 Optical Sensor 1. Slide the optical sensor into place, to position it with the optical disk between its upper and lower arms. The disk should never touch the sensor.
  • Page 60 4700 Refrigerated Sampler Service Guide Section 2 Sample Delivery System 2-30...

  • Page 61: Overview

    AC mains power. Table 3-1 con- tains part numbers for voltage-specific components, and for the refrigerator cabinet. For a complete listing of replacement parts, refer to Appendix B. Table 3-1 Replacement Parts for 4700 Refrigerator Refrigeration Module, 120V/60 Hz Entire Refrigeration Assembly 60-4704-028...

  • Page 62: Door

    3.3 Temperature Sensors The 4700 has two refrigeration temperature sensors, one attached to the evaporator coil to measure the evaporator tem- perature, and the other mounted on the refrigerator’s rear wall to measure the refrigeration air temperature.

  • Page 63: Location Of Temperature Sensors (Reverse View Of Module)

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System The evaporator temperature sensor is mounted on the sixth coil of the evaporator with two cable ties (Figure 3-1). The air tem- perature sensor is fastened to the rear wall of the refrigerator with a holder (Figure 3-1).

  • Page 64: Temperature Sensor Cable Wiring Connector

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System Figure 3-3 Control panel module removal 3. Lift the control panel to expose the wiring connectors, tak- ing care not to put strain on the wires. 4. Disconnect the temperature sensor cable from connector P5 on the control board (Figure 3-4) and set the panel back in place.

  • Page 65: Temperature Sensor Wiring Entry At Rear Of Cabinet

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System fan (Figure 3-5). Unscrew the black cord-grip fitting from the bulkhead fit- ting in the refrigerator’s rear wall. Bulkhead fitting Cord-grip fitting Temperature sensor cable Figure 3-5 Temperature sensor wiring entry at rear of cabinet 8.

  • Page 66: (Seen From Rear With Power Supply Removed)

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System 6. Attach the new cable to P5 on the control board. 7. Align the control panel over the mounting holes and secure it with the mounting screws. Torque screws 1.8 to 2.0 Nm (16 to 18 in/lbs).

  • Page 67: Cpu Temperature Sensor

    The electronics compartment is protected from moisture conden- Sensor sation by an internal heater on the main CPU board. If the 4700 has been connected to AC power for at least half an hour, the temperature within the electronics compartment should be greater than the ambient temperature.

  • Page 68: Refrigeration Module

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System Figure 3-9 Temperature verification with the 24-bottle rack Figure 3-10 Temperature verification with the bottle locating base 3.4 Refrigeration Module The following sections describe inspection and servicing proce- dures for the refrigeration module.

  • Page 69: Refrigeration Service Ports

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System Refrigeration repairs are not performed by the factory, and on-site repairs are not recommended. Teledyne Isco recommends replacement of the refrigeration module in the event of com- ponent failure. If it is still deemed more practical to repair the system, on-site repairs must be performed by licensed service personnel only.

  • Page 70: Piercing Service Port .312 O.d. Tubing With A Saddle Tap Tool

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System Figure 3-12 Piercing service port .312 O.D. tubing with a saddle tap tool Suction line wrapped in cork tape High-pressure service port, covered with heat-shrink Figure 3-13 Protective coverings for suction line and service ports 3.

  • Page 71: Refrigeration System Troubleshooting

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System Table 3-2 Refrigeration System Troubleshooting Symptom Cause Action Plugged orifice Compressor tries to start, then stops, has excessive current draw Compressor failure Replace refrigeration module (recommended) Compressor runs hot, trips thermal breaker...

  • Page 72: Refrigerant Dryer, Before Installation And Coating

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System Refrigerant dryer Teledyne Isco recommends replacing the non-directional dryer any time a leak is repaired. Figure 3-14 Refrigerant dryer, before installation and coating Orifice The precision orifice through which liquid refrigerant changes temperature and pressure before entering the evaporator coil is a very delicate device, and is easily clogged.

  • Page 73: Refrigerant

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System Orifice Dryer Relay & Overload (120V box shown) Figure 3-15 Refrigeration module components (possible leak areas indicated by arrows) 3.4.2 Refrigerant On-site charging must be performed by licensed service per- sonnel only. Consult your local laws regarding refrigeration repair.
  • Page 74 4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System 2. Through the high pressure service port, pressurize the sys- tem with dry nitrogen before charging to ensure that there are no leaks. If there is a leak in the refrigeration system, replacement is recommended.

  • Page 75: Refrigeration Charging

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System Wrap suction line in cork insulating tape. Service Port (high pressure) Shrink Tubing Service Port (low pressure) Figure 3-16 Refrigeration charging 3-15...

  • Page 76: Condenser Fan

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System 3.4.3 Condenser Fan The condenser fan rarely needs replacement. A bent fan blade, debris blockage, or loose connection can often be corrected by hand. In the rare case of fan motor failure, replace the fan.

  • Page 77: Removal/Replacement Of Condenser Fan

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System 2. The fan harness has two thick, black wires, one smooth and one ribbed, ending in female flag terminals (120V) or female spade terminals (230V). Disconnect the wires from the relay (Figure 3-18).

  • Page 78: Module Replacement

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System 5. Route the fan harness around the drip tray and connect to the relay, taking care to connect the ribbed and smooth wires correctly, as shown in Figure 3-18. a. For 230V units, also route the harness wires around the right side of the terminal box and under the top hold-down tab.

  • Page 79: Remove Power Cord

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System Bushing Figure 3-21 Remove power cord 2. Remove the electrical cover on the side of the compressor. 3. While holding the overload and relay in place, disconnect the solid blue and solid brown wires from the side of the compres- sor.

  • Page 80: Electrical Connections On 230V Compressors

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System Smooth Grn/Y Ribbed Figure 3-23 Electrical connections on 230V compressors 4. The evaporator sensor is mounted on the sixth coil up on the evaporator. Cut the ties holding the evaporator sensor in place and move it out of the frame.
  • Page 81 4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System Module installation 1. Use two new cable ties to attach the marked temperature sensor to the evaporator coil in the location, as shown in Figure 3-1. Note The sensor must be mounted in the correct position in order to operate correctly.

  • Page 82: Refrigeration Cool Down Test

    4700 Refrigerated Sampler Service Guide Section 3 Refrigeration System 3.5 Refrigeration Cool Before beginning the cool down test, look inside the refrigerator to ensure that the evaporator fan is running. Down Test For the cool down test to pass, the temperature inside the refrig- erator must drop at an average rate of at least 0.5 degrees per...

  • Page 83: Section 4 Cpu And Power Supply

    4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply This section contains circuit descriptions of the 4700’s CPU and power supply, as well as functional CPU board testing. Sche- matics can be found at the end of the section.

  • Page 84: Memory - U26, 27

    4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply The processor has a 16-bit data bus so that two bytes at a time are handled between the CPU and memory. Eight bits of the data bus also go to the LCD display. The logic for address decoding is built into the CPU, so there is no external logic to generate the chip selects to the memories and display.

  • Page 85: Serial Port - U32

    4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply U12 is another switching regulator that produces 5 volts. This voltage is used by the display backlight and the general outputs. Vp goes through a linear regulator (VR1) to become 5 volts for the circuitry of the LCD display and its associated circuitry.

  • Page 86: Distributor Motor Drive - U1, P1/Rotation Sensor - P4, U9

    4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply battery can be monitored by the CPU through the resistor divider network R77-78. The CPU can load the battery by turning on FET Q8 for testing the battery. This chip also has an unused watchdog function.

  • Page 87: Case Heater - U25

    4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply When the pump is called into operation, the Pump Encoder Drive signal goes out through U37 to P8, thus turning on the LED in the pump opto. Pump pulses come back in as the pump turns, go through Schmidt trigger U9-D, and into the CPU.

  • Page 88: Test Points

    Section 4 CPU and Power Supply 4.2 Test Points Test points and their values for the 4700 CPU are listed below in Table 4-1. See the schematic diagram in Figure A-5, Appendix A, which shows their board connections in red for easier viewing.

  • Page 89: Cpu Board Tests

    4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 4.3 CPU Board Tests The tests described in this section are accessed through the serial port (interrogator port) with a terminal emulation program such as HyperTerminal. To connect the sampler to a computer, use the optional 3.8 m (12.5 ft) RS-232 serial communication cable, 69-4704-042.

  • Page 90: Cpu Board Functional Tests

    Section 4 CPU and Power Supply actual test results will appear on your computer screen, the text displayed on the 4700 can be ignored, except in the case of the display tests. Each test is independently accessed by sending a command...
  • Page 91 4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Table 4-2 CPU Board Functional Tests (Continued) Function Command Results Electronics Test RAM Returns OK or NOT_OK Loads and reads back the four 16-bit words FFFF, 0000, a5a5, and 5a5a in RAM.
  • Page 92 4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Table 4-2 CPU Board Functional Tests (Continued) Function Command Results Refrigeration/Temperatures Test refrigeration A pulse is output first on the compressor control input and output (5V on P14-1), then the refrigerator...

  • Page 93: Control Panel

    T99 test. time/date has not been saved.) 4.4 Control Panel Some issues involving the 4700 control panel may be software related. Verify that the sampler has the latest software version 60-4704-031 (see Section 1.5.1 Updating the Software). Some problems may be...

  • Page 94: Control Panel Installation

    3. Reinstall the control panel screws and tighten down uni- formly and snugly (16 to 18 in/lbs). 4. Reconnect power and perform all diagnostic tests (refer to the 4700 Installation and Operation Guide, Section 5-2). 4-12...

  • Page 95: Control Panel Connector Identification And Wiring

    4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply P8 P9 P5 P7 Figure 4-2 Control panel wiring connectors Table 4-3 Control Panel Connector Identification and Wiring Pump Rotation Distributor Motor Sensor 2 3 4 External Device Pump Latch...

  • Page 96: Power Backup

    Section 4 CPU and Power Supply 4.4.3 Power Backup Current models of the 4700 have the capability of switching the sampler controller to backup power from an Isco power supply in the event of AC power loss. Older models can be modified to have this capability.

  • Page 97: Power Supply

    4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 4.5 Power Supply The 4700 power supply is the same for 120V and 230V samplers. A plug adaptor is provided 230V samplers. 120V 60-4704-040 230V 60-4704-062 4.5.1 Recent Changes to the...

  • Page 98: Fuse

    4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Figure 4-4 Power supplies: old and new (protective cover removed) 4.5.2 Fuse The new power supply has a fast blow, 4A/250V, 5mm x 20mm glass fuse to protect the sampler controller. This replaceable fuse is located on the converter board, behind the white AC connector (you may need to disconnect this connector to access the fuse).

  • Page 99: Power Supply Removal

    4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 4.5.3 Power Supply Removal The power supply is replaced as a whole unit, complete with attached cables. To access the power supply, first remove the refrigerator’s cover brace, back cover, insulation, and refriger- ation module, as described in Section 1.8 Accessing the Rear...

  • Page 100: Remove Power Cord

    4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Bushing Figure 4-7 Remove power cord 2. Disconnect the two wire connections on the side of the com- pressor, and the green and yellow ground wire from the module chassis. These three wires come from the power supply.
  • Page 101 4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Smooth Grn/Y Ribbed Figure 4-9 Electrical connections on 230V compressors 3. Following the steps for removing the control panel in Sec- tion 4.4, disconnect the two power supply harnesses from the circuit board connectors P11 and P14 (Figure 4-2).
  • Page 102 4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 5. Gently loosen the bulkhead fitting with a 1" open wrench and unscrew it from the refrigerator cabinet. Pull the con- trol panel power cable out through the threaded opening.

  • Page 103: Power Supply Replacement

    4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Figure 4-13 Power supply back plate and mounting screws 4.5.4 Power Supply 1. Mount the replacement power supply with the two Phillips Replacement screws. 2. Reconnect the wires to the compressor and replace its cover.

  • Page 104: Line Cord

    4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Note When reinstalling the fan, ensure that the red power connector goes to the red wire terminal and the black power connector goes to the black wire terminal (see Figure 4-12).
  • Page 105 4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply torx screws Figure 4-15 Remove power supply cover 2. Remove the lock nut holding the line cord ground connec- tor on the mounting plate (Figure 4-16). 3. Disconnect the blue (-) wire from W3 on the power board, and the brown (+) wire from W4 on the power board (Figure 4-16).

  • Page 106: Line Cord Replacement

    4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Ground wire W3 W4 +/- wires Figure 4-16 Line cord connections 4. Using the open-end wrench, unscrew the black plastic nut from the line cord bulkhead fitting and pull the old cord out through the hole in the mounting plate (Figure 4-17).
  • Page 107 4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply Note Before connecting, route these wires under those of the com- pressor cord, as shown in Figure 4-16, to prevent them from being caught under the edge of the protective cover.
  • Page 108 4700 Refrigerated Sampler Service Guide Section 4 CPU and Power Supply 4-26...

  • Page 109: Section 5 Electrical Troubleshooting And Diagnostics

    4700 Refrigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics 5.1 4700 Diagnostics The sampler has built-in diagnostics routines that trained service technicians use to confirm that all sampler subsystems are working correctly or to locate faults. Many of the diagnostic routines also can be run in the field.

  • Page 110: Test 'Ram

    3. When finished, the sampler displays the test results. 'RAM' PASSED If the sampler reports ‘RAM’ FAILED contact your authorized Isco service facility or the Teledyne Isco factory. 5.1.2 Test ‘ROM’ The TEST ‘ROM’ diagnostic tests the sampler’s Read-Only Memory which holds the sampler software. It calculates a checksum total of the data held in this memory and compares it with a known value.

  • Page 111: Test Keypad

    Section 5 Electrical Troubleshooting and Diagnostics · poor contrast If any of these or other faulty display conditions exist, contact your authorized Isco service facility or the Teledyne Isco factory. 5.1.4 Test Keypad The TEST KEYPAD diagnostic tests the sampler’s keypad. While the test is active, the display reports the button name of any button you press.

  • Page 112: Test Distributor

    4700 Refrigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics If the sampler displays PUMP FAILURE or BAD ON/OFF RATIO, turn off the sampler by pressing the Off button. Then, refer to Section 1.4.1 and perform a pump inspection. Clear any obstruc-...

  • Page 113: Distributor Arm Positioning, Discharge Tube Removed

    TEST DIS- TRIBUTOR diagnostic again from step 1. If you don’t find obstruc- tions to the distributor arm movement, contact your authorized Isco service facility or the Teledyne Isco factory.

  • Page 114: Test Flow Meter Port

    Isco service facility or the Teledyne Isco factory. They will be able to assist you with obtaining a test plug or making the necessary jumper connec- tions to run the test.

  • Page 115: Input Voltage

    Stop or Enter button. __._ C If you suspect that the internal heater is not working, contact your authorized Isco service facility or the Teledyne Isco factory. 5.1.10 Input Voltage The INPUT VOLTAGE diagnostic displays the Main CPU board’s DC voltage supplied by the power module. When this test is started, the sampler will display the input power until you press the Stop or Enter button.

  • Page 116: Loaded Battery Voltage

    4700 Refrigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics Note Should there be a loss of AC power and the internal battery’s no-load voltage is below 2.2 VDC, the sampler might lose data and settings from its memory. It is recommended that you retrieve the data and record the program and configuration set- tings in case of memory loss.

  • Page 117: Hidden Menu Functions

    10 seconds. The reading should be within half a milliamp of the actual current input. 5.2 Hidden Menu The 4700 Sampler has several hidden service screens. These screens are accessed by entering a numerical code number from Functions the standby menu screen.

  • Page 118: Compressor Control

    4700 Refrigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics Power Supply cover plate Reach through to access cover plate Figure 5-3 Manual check of compartment heater operation Note that the compressor and heater can only turn on and off...
  • Page 119 4700 Refrigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics Table 5-1 Service Menu (7378423): Compressor and Heater Control Value Degrees C Degrees F Value Degrees C Degrees F -0.4 62.6 64.4 66.2 69.8 71.6 10.4 73.4 12.2 75.2 15.8...

  • Page 120: Fan Control

    TEST FLOWMETER PORT requires a test plug in the 16 pin YES/NO communications interface port. This test is the same as the Test Flow Meter Port test under Section 5.1 4700 Diagnostics. REINITIALIZE will restart the software and initialize all vari- ables.

  • Page 121: Pump Information

    Up to 24 positions can be con- figured. To enable this option, enter the code 1709. The message 1709 will appear for several seconds. When the OPTION ENABLED standby screen reappears, enter 2688537 (BOTTLES). For assistance with setting up this option, contact Teledyne Isco. 5-13...
  • Page 122 4700 Refrigerated Sampler Service Guide Section 5 Electrical Troubleshooting and Diagnostics 5-14...

  • Page 123: Appendix A Electrical Diagrams

    Figures A-2 and A-3, respectively. A-4 shows board func- tions, connections, and color-coding for all harnesses and cables. See Figure A-5 for a schematic diagram of the 4700 CPU CBA. The schematic shown is for the current version with battery backup capability.
  • Page 124 4700 Refrigerated Sampler Service Guide Appendix A Electrical Diagrams...
  • Page 125 4700 Refrigerated Sampler Electrical Wiring 4700 Refrigerated Sampler Electrical Wiring Figure A-2 4700 wiring diagram - 120V...
  • Page 126 4700 Refrigerated Sampler Electrical Wiring Figure A-3 4700 wiring diagram - 230V...
  • Page 127 W12 W13 W14 W15 Sample Evap Temperature Temp Stepper Probe Motor (optional) Temp 1 2 3 1 2 3 4 5 Flow Meter / Interface Cable Chassis Piezo Film Interlock Comp. Pump Motor Condensor Fan Figure A-4 4700 board connectors and functions...
  • Page 128 4700 Refrigerated Sampler Electrical Wiring Figure A-5 4700 CPU schematic diagram...

  • Page 129: Appendix B Replacement Parts List

    4700 Refrigerated Sampler Appendix B Replacement Parts List Replacement parts are called out in the following pages. Refer to the call-out in the adjacent table to determine the part number for the item. Replacement parts can be purchased by contacting Teledyne Isco’s Customer Service Department.

  • Page 130: Sampler/Refrigerator Replacement Parts

    4700 Refrigerated Sampler Appendix B Replacement Parts List B.1 Sampler/Refrigerator Replacement Parts...
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  • Page 159 4700 Refrigerated Sampler Appendix B Replacement Parts List B-31...

  • Page 160: Bottle Configuration Replacement Parts

    4700 Refrigerated Sampler Appendix B Replacement Parts List B.2 Bottle Configuration Replacement Parts B-32...
  • Page 161 4700 Refrigerated Sampler Appendix B Replacement Parts List B-33...
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