Drager 8000 SC, 8000 NC User manual

8. Repair Information Unit, Electronics Module, Climatic Sensor

Table of Contents

8.1Unit................................................................................................................................2

8.1.0Table of Contents...................................................................................................2

8.1.1Information on Unit 2M 20 276 / 2M 20 615 (of Inc. 8000 SC/IC/NC)....................3

8.1.2PCB Unit and Fuses...............................................................................................3

8.1.3Air Heating with Thermal Release..........................................................................6

8.1.4Boiler with Water heating and Thermostatic Switch...............................................6

8.1.5Fan Motor...............................................................................................................8

8.1.6 Mains Transformer...............................................................................................10

8.1.7Semiconductor Relay...........................................................................................10

8.1.8Test of Heating Unit (Complete)...........................................................................11

8.1.9Voltage Selection.................................................................................................26

8.1.10Replacement of Unit in the event of Repair..........................................................27

8.1.11Repair Information and Change Status................................................................27

8.2Electronics module......................................................................................................28

8.2.0Table of Contents.................................................................................................28

8.2.1Keyboards............................................................................................................30

8.2.2PCB Display Air Temperature..............................................................................36

8.2.3PCB Display (of options), PCB Display Skin (as of SW 11 and 21).....................39

8.2.4PCB Display Humidity (only Inc. 8000 SC/NC)....................................................42

8.2.5PCB CPU..............................................................................................................44

8.2.6PCB Analog with PCB Filter.................................................................................56

8.2.7PCB Power Pack..................................................................................................74

8.2.8PCB Motherboard and PCB Fan..........................................................................80

8.2.9PCB Switch...........................................................................................................84

8.2.10N/A.......................................................................................................................84

8.2.11PCB Controller (RS232) 82 90 581......................................................................85

8.3Climatic sensor............................................................................................................90

8.3.0Table of Contents.................................................................................................90

8.3.1Information on Climatic Sensors..........................................................................90

8.3.2Climatic Sensor 82 90 380 and 2M 21 688..........................................................91

8.3.3Testing and Adjustment........................................................................................92

8.3.4Replacement and Repair......................................................................................95

8.3.5Repair Information and Change Status................................................................96

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8.1 Unit

8.1.0 Table of Contents

8.1.3

H2O

Air

8.1.5

8.1.4

8.1.7

8.1.6

8.1.2

8.1.1 Information on Units Used

8.1.2 PCB Unit and Fuses

8.1.3 Air Heating with Thermal Release

8.1.4 Boiler with W ater Heating and Thermostatic Switch

8.1.5 Fan Motor

8.1.6 Mains Transformer

8.1.7 Semiconductor Relay

8.1.8 Testing of Unit (Complete)

8.1.9 Voltage Selection

8.1.10 Replacement of Unit in the event of Repair

8.1.11 Repair Information and Change Status

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8.1.1 Information on Unit 2M 20 276 / 2M 20 615 (of Inc. 8000 SC/IC/NC)

Characteristics:

PCB Unit 82 90 511

- All connections to printed circuit board plugged-in

- Heating cartridges for one mains voltage only (100 V, 120 V / 127 V or 230 V / 240 V)

- Boiler (complete) plugged-in. In the Inc. 8000 SC/IC/NC it can be removed through a service opening without dismounting the Unit

Since both Units are identical as far as their function is concerned it is possible to use the Unit 2M 20 615 in the Inc. 8000, refer to 8.1.9 "Replacing in the event of Repair".

8.1.2 PCB Unit and Fuses

Layout Component Mounting Side:

T58

T57

100

110

127

230

T60

240

T3 T4 T2 T5

T41 T42 T43 T44

T54

T56

T59

F1 F2

X12

T61

X10

X11

X3 X4

T53

F5 F6 F7 F8 F9 F10

T55

T7 T10 T9 T8 T63

C2 +

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Layout Rear:

X13

Component Mounting without Fuses:

Position Component Function

X1 Connector 18 13 641 Cable connection to electronics module X2 Connector 18 13 544 Cable connection to valve(s) X3, X4 Terminal 68 04 759 Mains connection X5 Connector 18 10 669 Connection for coil of fan watchdog,

Thermostatic switch water shortage and

control of semiconductor relay X6 Connector 18 28 592 Connection mains voltage for transformer X7 Connector 18 28 576 Return transformer voltages X10 Connector 18 28 533 Connection heating cartridge for water

heating X11 Connector 18 28 541 Connection semiconductor relay supply side X12 Connector 18 28 525 Connection heating cartridge of air heating X13 Connector 18 28 533 Connection fan motor K1, K5 Relay 18 30 732 Mains closing relay K2 Relay 18 21 474 Safety relay for heating K3 Relay 18 21 474 Safety relay for valve(s) K4 Relay 83 01 198 Safety relay for disconnection Semiconductor

relay of heating valve(s) T54 Transformer 18 13 927 Auxiliary transformer for mains closing relays

K1 and K5

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Fuses:

Position 100 V to 127 V 220 V to 240 V

F1, F2 T 6,3 A 18 15 172 T 3,15 A 18 15 148 F 3 T 80 mA 18 14 974 T 40 mA 18 14 931 F4 T 1A 18 15 083 T 500 mA 18 15 059 F5 T 200 mA 18 15 016 T 200 mA 18 15 016 F6 T 500 mA 18 15 059 T 500 mA 18 15 059 F7 T 2,5 A 18 15 121 T 2,5 A 18 15 121 F8 T 1,6 A 18 15 105 T 1,6 A 18 15 105 F9, F10 T 160 mA 18 15 008 T 160 mA 18 15 008

Testing:

Refer to 8.1.8 "Testing Unit (complete)"

Replacement in the event of repair:

In the event of repair the PCB Unit 82 90 511 (complete) can be replaced or components can be renewed. All relays are available for this purpose, refer to component mounting list.

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8.1.3 Air Heating with Thermal Release

Three different heating cartridges are uses i n this Unit:

- 220 V to 240 V (132 Ohm) 2M 20 329

- 120 V / 127 V (33 Ohm) 2M 20 331

- 100 V (25 Ohm) 2M 20 669 Prolonged heating cartridges are in use since 1992. When installing these heating cartridges

lock them using an M4-screw.

8.1.3.3 Thermostatic Switch

A safety thermostat which has been tripped must be replaced, no soldering permitted. Prior to replacement, determine cause for tripping, for example:

- wrong heating cartridges

- device assembled incorrectly The resistance of the thermostat can be checked at its contacts.

8.1.4 Boiler with Water heating and Thermostatic Switch

The boiler system is a plug-in unit consisting of:

- Aluminum housing 2M 20 291

- Heating cartridge for 230 V, 120 V / 127 V or 100 V

- Cap for vaporizer 2M 20 292

- O-ring cap 2M 08 777

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- Thermostatic switch water shortage alarm 115 °C 2M 20 381

- Safety thermostat 140 °C 2M 20 382

- Plug-in connector

All components can be replaced in the event of repair. If the safety thermostat has been tripped both thermostatic switches must be replaced.

Service:

The condition of the boiler housing must be checked every six months. If the vaporizer chamber is soiled it can be scraped out.

Heating cartridges:

- 220 V to 240 V (530 Ohm)2M 20 327

- 120 V / 127 V (132 Ohm) 2M 20 328

- 100 V (100 Ohm) 2M 20 668

Prolonged heating cartridges are in use since 1992. As before, the end of the heating cartridge must be flush with the boiler housing.

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8.1.5 Fan Motor

Fan motor (simplifi ed representation):

43,5 +/- 0,5

Service required:

The fan motor must be lubricated every six months with oil 2M 07 839. Procedure: Remove screw A located next to the motor shaft and apply approx. 10 drops of oil into the bore hole.

Bearing play:

The bearing play can be adjusted using screw B. The screw must be adjusted such to allow a motor shaft play of approx. 0.2 mm. The screw must be sealed with locking compound.

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Replacing the Fan Motor

Procedure:

- Interrupt mains connection to Incubator and remove Unit

- Unscrew coil of the fan watchdog from aluminum block of the motor mount

- Disconnect cable connection from motor to printed circuit board

- Unscrew fixing bracket underneath the motor

- Measure and write down dimension E of the 4 retaining screws

- Remove 4 retaining screws

- Using oil 2M 07 839 lubricate later bearing surface of V-ring C of the new motor

- Plug new motor with springs onto threaded pins and screw 4 retaini ng screw D onto dimension

- Precision adjustment: While the Unit is in its working position the motor shaft must protrude by

43.5 +/- 0.5 mm from the top edge of the aluminum block and must be positioned perpendicularly to the block. The motor must be suspended freely on the springs.

- Seal the 4 retaining screws D with Loctite 221.

- Lubricate the motor

- The remaining steps of the installation are performed in the reverse order

- When connecting the grounding rings make sure that they do not protrude from the edge of the resilient motor retaining plate. The fl at head screws of the motor retaining clip must be sealed with locking compound.

After installation into the Incubator make sure that the fan wheel does not rub against

the tank and that it can move freely on the spring-loaded bearing.

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8.1.6 Mains Transformer

- Transformer with Efen sensor 82 90 426

The test procedure is described under 8.1.8.3

8.1.7 Semiconductor Relay

The test procedure is described under 8.1.8 The following spare parts can be used in the event of repair:

- Semiconductor relay (electromagnetic or crydom 18 31 399 partial interference suppression)

- Semiconductor relay 18 21 148

Note: The semiconductor relays 18 31 399 have a better switching behavior.

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8.1.8 Test of Heating Unit (Complete).

8.1.8.0 Contents

8.1.8.1 Test equipment required

8.1.8.2 Preparation of test

8.1.8.3 Test of power-up relay and supply voltages

8.1.8.4 Test of fan monitoring

8.1.8.5 Test of relay K4

8.1.8.6 Test of relay K3

8.1.8.7 Test of relay K2, air heating and feedback air heating

8.1.8.8 Test of relay K2, water heating and thermo-switch

8.1.8.9 Test of heating unit inside incubator

8.1.8.1 Test equipment required

- Tester heating unit Inc. 8000 79 01 764

- Multimeter 79 01 021

- Measuring line, red 1 m 79 01 022

- Measuring line, black, 1m 79 01 023

- Mains line (only if heating unit is disassembled for test)

- 40-pole ribbon cable use the one of incubator or

"test board uni 40" 79 00 610

- 10-pole ribbon cable included in tester "heati ng unit"

Inc. 8000" 79 01 764 or use the one of "test board uni 40" 79 00 610

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8.1.8.2 Preparation of test

The heating unit of Incubators 8000 SC/ICNC can be tested while assembled or disassembled.

Note: If the unit is disassembled an isolating transformer must be used. Test set-up (Netzkabel = power cord):

PCB Unit (part of the heating unit)

- Interrupt mains connection

- Connect tester to X1 PCB Unit using cable

- Connect tester to X2 PCB Unit, the cable connection to the valve(s) must be interrupted before

- Set all switches at tester to "0" (off)

- Interrupt water supply to boiler of the heating unit

- Attach fan wheel

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- Establish mains connection to incubator (heating unit installed) respective to heating unit (not installed)

Set switch K1 at tester to "1" (on).

- Action inside the heating unit o Mains power-up relays K1/K5 (heating unit 82 90 511) on o Fan wheel turns

- Test of tester displays: o LED + 30 V lights up o LED 18 V ∼ F5 lights up o LED 18 V ∼ F6 lights up o LED 9 V ∼ F7 lights up

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8.1.8.3 Test Set-up for testing a Unit in the Field

It is possible to use the fol lowing test-up for testing the power unit in the field:

open up the unit

•

disconnect the electronic module

•

connect the power unit and the test box with the 40 pin cable

•

carry out the test procedures as given in the following pages (i.e. item 8.1.8.3 and

•

onwards)

Note: The 3 LEDs marked in the drawing below are not active in this test-setup.

Do not connect

40 pin conn.

- Measurement of supply voltages at tester o alternating voltage 18 V ∼ F5

test value: U= 18 V + 15 %

o alternating voltage 18 V ∼ F6

test value U = 18 V + 15 %

o alternating voltage 9 V ∼ F7

test value U = 9 V + 15 %

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o direct voltage + 30 V

test value U = 30 V + 4 V

Possible errors:

Error Possible cause

no reaction after switching of K1 - mains input fuses F1/F2 defective

- fuse F3, F9 or F10 of auxiliary mains transformer defective (F9 and F10 only on PCB 82 90 511)

- mains power-up relay K1 or. K1/K5 defective

- fuse F4 for mains transformer defective

- mains auxiliary transformer or rectifier behind mains auxiliary transformer on PCB defective

- Efen sensor of transformer defective

LED 18 V ∼ F5 off or voltage outside the tolerance

- fuse F5 defective

- transformer defective

- voltage changeover to PCB O.K.?

LED 18 V ∼ F6 off or voltage outside the tolerance

- fuse F6 defective

- transformer defective

- voltage changeover to PCB O.K.?

LED 9 V ∼ F7 off or voltage outside the tolerance

- fuse F7 defective

- transformer defective

- voltage changeover to PCB O.K.?

LED + 30 V off, fan wheel stops - fuse F8 defective

- transformer defective

LED + 30 V off, fan wheel turns - rectifier for + 30 V on PCB defective,

alternating voltage exists, because fan wheel

turns LED + 30 V lights up, fan wheel stops

- fan motor defective

- starting capacitor for fan motor defective

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Troubleshooting:

component to be tested test

fuses resistance measurement with disassembled fuses mains auxiliary transformer and rectifier behind mains auxiliary transformer Efen sensor transformer If after switch on the voltage on the PCB exists in

voltage measurement on the PCB via capacitor C2, test value approx. 12 V

front of the transformer, and no LED lights up on the tester, the transformer must be replaced. The voltage (mains voltage) is measured on the PCB between the soldering joint for mains voltage adjustment and fuse F4.

8.1.8.4 Test of fan monitoring

Prepare test as described in 8.1.8.2, test 8.1.8.3 passed.

Switch K1 at tester set to "1" (on), the fan wheel turns. Measurement of alternating voltage at tester at socket "feedback fan" and GND. Test value:

Measurement using an oscilloscope VSS > 2,8 V Peak to Peak

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in this respect only the negative half-wave is important

or (very inaccurate)

Measurement using multimeter: V > 0,6 V

∼

In the case where a high ohm multimeter is used, measure over a 10-20 KOhm resistor as follows:

10-20 K

Note: Observe service information No. 29 in case of

electronics module Incubator 8000 with PCB Motherboard 82 00 850, otherwise an excess output voltage might result in INOP error 9.

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Possible errors:

Error possible cause

Voltage cannot be measured - fan wheel properly attached?

- cable connection of PCB to coil of fan monitoring interrupted fan monitoring interrupted

- coil of fan monitoring defective (measure voltage directly at the coil with the heating unit disassembled)

voltage too low observe service information No. 1 (Inc.

8000SC/IC) and service information No. 31 (Inc.

8000), with Inc. 8000 observe service information No. 29!

voltage ok, but continuous fan

PCB Motherboard in electronics module failure alarm at the assembled incubator INOP-error 9 with assembled Incubator 8000

voltage too high, observe service i nformation

No. 29 for Incubator 8000. In Incubator 8000

SC/IC this means there is a failure on the PCB

Motherboard.

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8.1.8.5 Test of relay K4

Prepare test as described in 8.1.8.2, test 8.1.8.3 passed.

Switch K1 at tester set to "1" (on), LED "+ 30 V" at tester lights up. Test: LED at tester behind switch K4 off Switch K4 at tester set to "1" (on) Test:

LED at tester behind switch K4 lights up Switch K4 at tester set to "0" (off) Note: The voltage behind the switching contacts of relay K4 can be

measured at the socket behind switch K4 at the tester.

Possible errors:

Error possible cause

LED always off or no voltage relay K4 defective LED continuously lights up or vol tage exists continuously

relay K4 defective

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8.1.8.6 Test of relay K3

Prepare test as described in 8.1.8.2, tests 8.1.8.3 and 8.1.8.5 passed.

Switch K1 and K4 at tester set to "1" (on), LED "+ 30 V" lights up. Switch V1 and V2 set to "1" (on)

Test: LED V1 and V2 at tester light up. Switch K3 at tester set to "1" (on)

Test: LED V1 and V2 off Switch K3 at tester set to "0" (off)

Possible errors:

Error possible cause

LED V1 or V2 continuously light up relay K3 defective LED V1 or V2 continuously off relay K3 defective

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8.1.8.7 Test of relay K2, air heating and feedback air heating

Prepare test as described under 8.1.8.2, tests 8.1.8.3 and 8.1.8.5 passed.

Switch K1 and K4 at tester set to "1" (on) Switch K2 and HLR1 at tester set to "1" (on) Test:

Horn (high frequency) in tester on, air heating gets warm (do not allow to become too

hot, at 350 °C the thermostatic switch operates) Switch K2 set to "0" (off), the relay interrupts the power supply to the air heating Test: Horn in tester off Switch K2 set to "1" (on) Test: Horn in tester on Switch HLR1 set to "0" (off), the semiconductor relay of the ai r heating is switched off Test: Horn in tester off

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Possible errors:

Error possible cause

horn continuously off - relay K2 defective

- HLR1 of air heating defective

- air heating defective (hi ghly ohmic)

- thermostatic switch of air heating operates

- feedback defective

(line interrupt) horn cannot be switched off with K2 relay K2 defective horn cannot be switched off with HLR1 semiconductor relay HLR1of air heating

defective

Troubleshooting:

Component to be tested Test

Thermostatic switch air heating Resistance measurement approx. 0 Ohm, defective

switches must be replaced

Air heating Resistance measurement, different types of

heating cartridges may be used:

- 132 Ohm (230 V / 240 V)

- 33 Ohm (120V / 127 V)

- 25 Ohm (100V)

- 2 x 60 Ohm (230/115 V) Semiconductor relay HLR1 for air heating

For this bridge contacts of relay K2 on the PCB via the test points:

- PCB 82 90 511 and PCB 82 00 600 ≥ 4:

bridge test points T55 and T57

- PCB 82 00 600 - 3:

bridge between fuse holder F2 and solder tag T6 (connection air heati ng) Switch on heating via tester (as described in the test above); however, heating cannot be switched off via K2.

Relay K2 For this bridge HLR1 of air heating at the mains

side directly at HLR at connections 1 and 2. The front relay is the HLR for the air heating. Switch on heating via tester (as described in the test above), however, the heating cannot be switched off via K2

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8.1.8.8 Test of relay K2, water heating and thermostatic switch

Prepare test as described under 8.1.8.2, tests 8.1.8.3 and 8.1.8.5 passed.

Switch K1 and K4 at tester set to "1" (on) Test: LED "H2O-shortage" shows green light Switch K2 and HLR2 set to "1" (on) Test: Boiler gets warm, after approx. 5 to 15 minutes horn on and LED "H2O-shortage" shows

red light Switch HLR2 at tester set to "0" (off) Test: After 5 minutes max. horn off, LED "H2O-shortage" at tester shows green light again Repeat all test steps

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Possible errors:

Error possible cause

Boiler does not heat up, LED "H2Oshortage" continuously shows green light

- excess temperature switch at heating switched off

- heating cartridge defective (hi ghly ohmic)

- relay K2 defective

- HLR2 of water heating defective Boiler heats up, LED "H2O-shortage" continuously shows green light LED "H2O-shortage" continuously shows red light Boiler cannot be switched off by means

thermostatic switch water shortage defective (always closed) thermostatic switch water shortage defective (always open) HLR2 defective

of switch "HLR2"

Troubleshooting:

component to be tested test

excess temperature switch resistance test at resettable thermostatic switch

at boiler (approx. 0 Ohm). If switch has operated both thermostatic

switches at the boiler must be replaced. Semiconductor relay HLR2 of water heating

For this, bridge contacts of relay K2 on the PCB

via the test points:

- PCB 82 90 511 and PCB 82 00 600 ≥ 4:

Bridge test points T55 and T58

- PCB 82 00 600 -3:

bridge between fuse holder F2 and

solder tag T11 (connection water heating)

Switch on heating via tester (as described in the

test above), however the heating cannot be

switched off via K2 Relay K2 For this, bridge HLR2 on the mains side directly

at HLR at connection 1 and 2. The HLR of the

water heating is the back relay. It must be

possible to switch on the heating via the tester,

however, it cannot be switched off by means of

switch "HLR2", but only with switch K2.

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8.1.8.9 Test of heating unit in the incubator

Assemble incubator in operable condition and switch it on. Test: No INOP or error alarm after switch-on test Perform O2 calibration (not Inc. 8000 SC/NC) and increase O2-desired value by at least 5 %

by vol. compared to actual value Test: No error-alarm in O2-module Set humidity desired value to maximum: Test with water supply:

The humidity measured value rises after a few minutes

Test without water supply:

Water-shortage alarm after a few minutes. The heating is switched off by the control,

the boiler cools down and the warning is switched off. Repeat test several times. Measurement of power consumption of water heating

Measure power consumption of unit. After self-test briefly withdraw and insert the

environmental sensor, thus air heating is suppressed for 90 seconds and with switched-

on humidity module and at max. desired value now a pulsating current of approx. 0,5 A

(230 V to 240 V-units) or of approx. 1 A (100 V to 127 V-units) can be measured.

Note: By pressing the two desired value buttons in the humidity module switched on for

approx. 3 seconds, a "heating LED" can be called up in the humidity module. Thus the

control and the pulsating current can be compared.

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8.1.8.10 Testing of valves

As a special function the valve of Inc. 8000 IC can be triggered with the tester "heating unit Inc. 8000".

Prepare test set up as described in 8.1.8.2, but connect valve(s) to X2 on the PCB Unit, the previous cable connection to the tester is no longer used. The LEDs at the tester for "V1", "V2" and the LED behind K4 do not have any function now.

For switch-on set the following switches at the tester to "1" (on): K1, K4 and V1 or V2

8.1.9 Voltage Selection

Caution: The electrical height adjustment is only intended for a voltage range of (100 V to 127 V or 220 V to 240 V)! In Incubator 8000 SC/IC/NC also observe mains input fuses!

The following circuit must be modified on the PCB 82 90 511:

- Solder jumper on printed circuit board into desired mains voltage position, refer to

8.1.2 Layout. There are several versions avail able, therefore the marking for the mains

voltages on the printed circuit board shall apply!

- In addition, the following soldering jumpers for the auxiliary transformer need to be

soldered:

220 V to 240 V: soldering jumper T42 ↔ T43

100 V to 127 V: soldering jumpers T41 ↔ T42 and T43 ↔ T44

- Modify fuses on the printed circuit board, refer to 8.1.2.2 The heating cartridge of the air heati ng must be replaced:

- 220 V to 240 V 2M 20 329

- 120 V /127 V 2M 20 331

- 100 V 2M 20 669 The heating cartridge of the water heating must be replaced:

- 220 V to 240 V 2M 20 327

- 120 V / 127 V 2M 20 328

- 100 V 2M 20 668

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8.1.10 Replacement of Unit in the event of Repair

In the event of repair the Units for the Incubators 8000 and 8000 SC/IC/NC can be replaced by the Unit 2M 20 615. This order number includes heating cartridges, boil er and fuses for 120 V / 127 V. The Unit 2M 20 276 was only intended for one specific mains voltage and is no longer available.

8.1.11 Repair Information and Change Status

8.1.11.1 Boiler for Inc. 8000 SC/IC in Unit 2M 19 940 for Inc. 8000

The boiler system for Inc. 8000 is considerably easier to service. The boiler housing can be replaced at considerably less cost. For servicing purposes it is still necessary to remove the Unit because the housing of Incubator 8000 has no servicing flap.

The following parts are required for modification:

- Boiler modification kit 2M 20 680

- Boiler (complete) 230 V / 240 V 2M 20 618 or

- Boiler (complete) 120 V / 127 V 2M 20 619 The modification kit will be available as of approx. September 1993.

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8.2 Electronics module

8.2.0 Table of Contents

Position of the sub-assemblies in the electronics module:

8.2.8

8.2.11

8.2.5

8.2.7

8.2.6

8.2.10

8.2.9

8.2.28.2.38.2.38.2.3 / 8.2.4

8.2.1 (Ink. 8000)

8.2.1 (Inc.8000 SC/IC)

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8.2.1 Keyboards, Inc. 8000 NC/SC/IC

8.2.2 PCB Display Air Temperature

8.2.3 PCB Display (of options), PCB Display Skin

8.2.4 PCB Display Humidity (only Inc. 8000 SC/NC)

8.2.5 PCB CPU and Software-Information

8.2.6 PCB Analog and PCB Filter

8.2.7 PCB Power Pack and Voltage Controller

8.2.8 PCB Motherboard and PCB Fan

8.2.9 PCB Switch

8.2.10 Push Buttons for Height Adjustment (only Inc. 8000)

8.2.11 PCB Controller (RS232)

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