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1. CPU BOARD POWER CONTROL BOARD 34 TO 4 BATTERY BP JIO J13 p i Lj paag mot AT UD a VA 2 KEYPAD id RIBBON __
2. dh Information contained in this document is the property of CEM Corporation and may 2 Corporation not be copied reproduced or distributed without the express written consent of CEM CPU BOARD POWER CONTROL BOARD 34 IO 4 EPROM J3 J5 J10 dS poe g mn ul T O JI U28 B KEYPAD RIBBON J16 fo DISPLAY RIBBON T 1 Jm FH Grrr fa FE 20 Q 4J6 Jt a J8N JI I Jg IR E i v5 N gc POWER 20 TO 23 IR 57 TO 60 SOLENOID 32 33 INT SW 15 16 STIRRER MTR 30 31 Discover 908005 Sheet 9 of 9 Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM itz Corporation
3. Information contained in this document is property of CEM Corporation and may Corporation not be copied reproduced or distributed without the express written consent of CEM Guide Block 163255 Pressure Note Orientation p Support of Fingers 163190 Spring Plunger BR198062 Socket Head Capscrew 4 BR196446 Gripper Support 163215 Socket Head Capscrew 4 BR196446 Pressure Phillips Truss Clamping y Head Screw Bracket BR128200 163210 w Loctite Standoff Standoff BR199022 Keps Nut 2 Pressure BR130261 Transducer Assembly 541122 Phillips Truss Head Screw 2 BR196014 Phillips Pan Head Screw 2 BR128200 w Loctite BR199022 Phillips Truss Head Screw BR128205 Ji Yellow C O White From Pressure Module Green gt Brown d Match Colors Gc Blac TP White o c Tp Blagk io From Belden Cable Match Colors Pressure Interface Keep Twisted Board 541470 Pairs Together Z Axis 163500 BR198899 Guide Block w Loctite w Loctite 163255 BR1
4. jo 1530030 NOAN 7 7 13388 wos qun 39 OL SNIAHO CED INN 7 ALITHINONDO 8 820051 ON SM3H LLVIN NOI LY80480 N39 ioLODT M ONIAYYG NOLLVHOdHOOS 99 Z IM W01 ALIWVIMDIQN3QU3d T TOOMAS 9 NALYO Y CaLVYANSS YALNdWOD 9 EX DW 10 10 20 nad 0350 38 NI 0 YIYO 33114915 HLIM N32 OL O31LINGE y yg Noii3rosa 319v 31VO 0332382 31VO N31LIUK NOAN 1 j8 01 JUV NOILIFdSNI 31719114Y 15813 803 51874 oN jaw OH TES OON S00 FXX 910 X OEO FC SE ONISVHINNA AO11804800 N39 03141234S ISIMYJHLO SSIINN S32NY33101 4802 9I1VN3H2S WALSAS YAAOISIG 2530 40 JHL SI INIMYYO SIKL Q3LON SSIINN 532 783701 1YY3N39 d AW 1dS10 SQVdA3M 105 3 mee 44708 dol we Quvog WOLIOG VH 8708 Add q TAND8 9 Sd AlddhS 3MOd 9VN 9 Aldd S Uu3MOd 9NIHOLIMS GND ALIAVO pL N MS W11910 5780 ZH 09 10 06 JWA 02 072 g ZH 09 OVA OZI lt XT z 131NI u3M0d NS iv ONOD3S nmm Som SOvdA34 2 Q300V 8 20 8 01 v Mad 5NINVHO 030551 Y 10 2 11 6222 NOI UG 40538 NOISIA3U WAS 3190 43
5. BROWN 10 BLUE WIRES MAGNETRON FAN POWER SUPPLY FAN BLACK 25 VA 26 29 P s A A N RED 24 7 hax 2E RED 27 mn og RED 7 29 COOLING SOLENOID STIRRER MOTOR MAGNETRON Ee z WHITE 67 WHITE 66 c RED 30 BLACK 31 ORANGE 5 BLACK 32 DC POWER SUPPLY O O WAVEGUIDE i5 212524 GROUND POST BROWN 6 17 64 69 8 E BLUE 7 GRN YEL BRI 30262 g 2 GRN YEL STL NUT 4 17 18 Discover 908005 Sheet 8 of 9
6. Point to Point Correct Readings Incorrect Step Meter Function Red Black U11 installed U11 removed U11 installed 1 diode F F H OL OL OV 2 diode F H F 0 4 0 6V 0 4 0 6V OV 3 diode PH E H 1 7 1 9V ramp up OL 2 4 diode F J K OL 0V 5 diode J M OL OV 6 diode F K Z OL OL OV 7 diode PF M Z OL OV 8 diode PH K J 0 4 0 6V 0 4 0 6V 0V 9 diode M J 0 4 0 6V 0 4 0 6V 0V 10 diode PH Z K 0 4 0 6V 0 4 0 6V 0V Il diode PF Z M 0 4 0 6V 0 4 0 6V 0V 12 diode B C 0V 13 diode PH C B 0 4 0 6V 0 4 0 6V OV 14 diode F 1 7 1 9V ramp up OL 2 15 diode F Y X 0 4 0 6V 0 4 0 6V OV 16 diode H XY OV 17 ohms Q A V 10Q 100 gt 110 18 ohms E T 100 100 Page 14 of 21 02 10 04 hv test doc rev A High Voltage Board Test Protocol General Debug Guidelines for Power Transistors Generally 10 Check R45 amp R46 12 As a part is determined to be faulty remove it immediately Otherwise any remaining measurements may be skewed Check Q4 D3 Q2 in that order If the fuses were blown Q4 most certainly will be shorted When replacing Q4 or Q2 replace U11 since it is likely compromised If Q4 is shorted P measurements of either polarity on a good D3 will produce a single diode drop If diode bridge D3 has a shorted diode probably Q4 will
7. Automated Synthesis ISCOVer Focused Synthesis oF w Flow Through ynthesis Microwave Synthesis Instrumentation Service Manual SM 0031 Rev 8 CEM s modular family of microwave synthesis instrumentation begins with the Discover module for focused synthesis x lt The Explorer module expands the capabilities of the Discover module with high throughput reaction handling capabilities The Explorer module installs on top of the Discover module The Voyager module a flow through reaction system further expands the capabilities of the Discover module for rapidly synthesiz ing larger quantities of compounds for laboratory scale up Methods developed on the Discover or the Explorer transfer directly to the Voyager The Voyager module also installs on top of the Discover module Introduction The CEM Focused Microwave Synthesis System Model Discover is designed to enhance the ability to perform chemical reactions under controlled conditions on a laboratory scale The CEM Automated Synthesis System Model Explorer is designed to add automated reaction handling capabilities to the Discover instrument The Focused Microwave family of instruments enhance the ability to perform chemical reactions under controlled conditions on a laboratory scale These systems facilitate either homogeneous or heterogeneous solution phase chemistry solid phase chemistry or chemistry conduc
8. Spring Limit E d BR198011 Switch Phillips A 1 119775 22 2 O 86196018 471 c L LO Vessel In Position Phillips Pan Head Screw 2 163855 BR196452 Bracket 163785 Explorer IntelliVent Pressure Module 541650 Sheet 2 of 2 Information contained in this document is the property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Corporation Pressure Calibrator Assembly for IntelliVent Pressure System 541356 Pressure Calibrator Assembly for Direct Pressure Transducer 541355 Pressure Calibrator Assembly 133HS 3138 11831 VN E IN SM3HLLVN ET ON IMVUQ NOIIVM 08803 N3O 031V43N39 YILNdNOD E oro NOILD3 0Ud 319NV QUIHI 1405 ETT __ L Q13HQNYH 3AISVANI NON YOLIINNOD NIG SOd 8 1531033 NOdf Q380013U 38 01 9NIMYUQ N011V00480 N3 303 3121 LUV 30 IUNLIVINNYN JHL 143913 3500919 ANY 603 0351 38 30 NOISSINY N3LLIYM 0 NOdN 103213 JON TIVHS ONY 2N SMIHLLVN NO11V80400 N39 930 Luv 10 12930084 JHL SI SNC SIHL HIDE 7 7 CUIL 77 ALIOVINDIQNSdHId T 108415 ONILVOIGNI at VIVO NOI1234SNI 53119915 HLIM WJD OI Q311IN3U 38 01 JUV NOI123dSNI 3121197 15813 803
9. ABCD Position 0 Left Right Position a w sof Default Substract offset with move Save QD Data Help Exit 22 Locate the Absolute Move section in the upper left side of the Explorer Setup screen The Ex Sys Status should read 0 indicating that the instrument components are communicating properly H Absolute Move Increment Ex Sys Status 0 000000 SW 0 Clamps 05 Ex Stopped End g 8 2003 9 19 55 AM Time Note If the Ex Sys Status reads 20 the instrument is not communicating properly Turn off the computer unplug all instrument modules replug all modules and check the serial port connections between the instrument and the computer If the Ex Sys Status continues to read 20 contact CEM 23 Locate Home section in the top left side of Explorer Setup screen Click the All key The Explorer automation module arm will raise the table will move to the right and the racks will move in and out until all have reached the home position 24 Remove the plastic protective cover from the gripper fingers 25 Locate the Z Axis information in the upper right corner of the Explorer Setup screen Z Axis H Up 1000 Rack Grip 8800 r Atten Drop 22200 mm Atten Grip 22600 Lock 26000 26 Click the R read button to read the instrument Z axis information Wait until the data is displayed
10. 92443215 V SIXV X QNnOU5 Sd Qquvog fd2 QN97NI1VN ZH 09 10 0G VA Miis ZH 09 021 JINON AYINI YIMOd E ar exe QNIAVEG 021551 2076 01 86621 N23 040934 NOISIA3U 11 0 438 L 9 S V IN39 10 sseJdxe y Jo peonpoudai peidoo eq uoneJodjo Aew uogesodiog W3 Jo Ayedoid y si jueuunoop 519
11. 12 13 14 15 16 17 18 19 20 Place the Discover module in an appropriate position as outlined previously in this manual Remove the top cover lid from the Discover module by pressing lightly on the secure tab at the rear center of the lid while slightly lifting and pulling backward on the lid to disengage the front insert tabs Remove the five 5 screws securing the top cover of the Discover module two in front one for the condenser location and two in the rear of the cover Discard the screws but retain the washers from the screws in the rear of the instrument for reinstallation Install the Explorer automation module attenuator Turn the attenuator clockwise sufficiently for the switches to lock into position Place the Explorer automation module support plate on the Discover module ensuring that the plate is positioned as far forward as possible to permit proper alignment of the Explorer automation module Secure the Explorer automation module support plate with the five 5 long screws included with the Explorer automation module tightening the screw in the center of the plate first Install the washers retained in step 3 on the two screws installed in the rear of the cover CAUTION Never lift the Explorer automation module by the vertical arm or movable table that holds the racks Lift the Explorer automation module by the base and place it on the support plate Loosely install one of the
12. Ware LLL LAN Spring Qy NG Ir arino Finger Spring BR198002 Finger 4 163740 Bearing 163675 Transducer Cap 163765 Pressure Transducer 119765 Transducer Spacer 163815 p Sensor Body 163710 Finger 163720 Super Lube BR199188 E ring BR199166 Discover IntelliVent Pressure Module 541660 Sheet 1 of 4 Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Phillips Pan Head Screw 3 BR196450 Motor Mount 163735 163725 Spring Pin BR198009 Socket Head Capscrew 2 BR197528 Switch 5 Lever G 163730 4 os ti Spring 2 BR198010 Motor Gear Motor Assembly 119770 541655 Limit Vessel In Position Switch 2 Spring 119775 J BR198011 Phillips Pan Head Screw 2 BR196018 Phillips Pan Vessel In Position Head Screw 4 BR196452 163855 Bracket 163785 Discover IntelliVent Pressure Module 541660 Sheet 2 of 4 Information contained in this document is property of CEM Corporation and may Corporation not be copied reproduced or distributed without the express written consent of CEM Mount Riser 163860 Phillips Pan Head Screw 2 BR128205 Socket Head
13. BR109977 m Gripper Valve Assembly Phillips Pan rd Head Screw 2 ERES BR128210 gt 95 O S Q o 0 Phillips Truss Motor Head Screw 2 Bracket BR199426 163045 Slotted Pan Head Screw 2 Pd BR196443 Motor 119615 Explorer Base Assembly 541415 Sheet 6 of 10 Information contained in this document is the property of CEM Corporation and may Corporation not be copied reproduced or distributed without the express written consent of CEM Standoff 4 BR198899 w Loctite BR199022 Keps Nut BR130262 Phillips Pan Head Screw 4 BR128200 Ground Stud Power Supply 119610 Base Plate 163005 Air Line Tubing from Wiring and Tubing Manifold Routed Through This Opening Keps Nut BR130262 Phillips Pan Head Screw 4 BR196081 Explorer Base Assembly 541415 Sheet 7 of 10 Information contained in this document is the property of CEM Corporation and may Corporation not be copied reproduced or distributed without the express written consent of CEM Stepper Motor 119620 Motor Extension Wire Harness PA 119730 wire Fitting 163355 Motor Assembly 541460 ES Expandable r Braided Sleeving 6 Tower BR198862 Pressure Cover Cover 163125 163120 Phillips Truss Head Screw 3 Wire Clamp BR199403 BR109976 Rear Phillips Truss Pressure
14. Fan Guard BR198061 Nut 2 BR130261 Manifold Assembly Note Fan wires this side 2 Cu J 3 j Screw 2 Cover Power BR196013 Fuses 163110 Module BR188280 1 Green Yellow Explorer Base Assembly 541415 Sheet 1 of 10 Information contained in this document is the property of CEM Corporation and may Corporation not be copied reproduced or distributed without the express written consent of CEM Cap Screw 8 BR196441 w Loctite Note Loctite All Screws with BR199022 Loctite 242 BR199022 Guide Block 4 163075 Fillister Head Screw 12 BR196080 w Loctite BR199022 Cap Screw 2 Positioning BR196444 Table 163060 Rail 4 163075 Cap Screw 2 BR196442 End Plate Rail 163065 Without Stops 163070 Slide Assembly 4 Socket Head Capscrew 16 BR196446 Explorer Base Assembly 541415 Sheet 2 of 10 Corporation Information contained in this document is the property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Phillips Pan Head Screw 2 BR128200 w Loctite BR199022 Align Motor Coupling 74 163295 i A 5 e Flush Against Recessed Edges Os p Base Plate 163005 Anti Backlash Nut 163085 Phillips Pan Head Screw 2
15. High Voltage Board Test Protocol Thermistor Temperature vs Resistance Table Temp C Rt ohms Temp C Rt ohms Temp C Rt ohms 0 32651 34 6807 68 1876 1 31031 35 6530 69 1813 2 29501 36 6266 70 1752 3 28054 37 6014 71 1693 4 26688 38 5774 72 1637 5 25395 39 5544 73 1582 6 24173 40 5325 74 1530 7 23016 41 5116 75 1480 8 21921 42 4916 76 1432 9 20885 43 4724 1385 10 19903 44 4542 78 1341 11 18973 45 4367 79 1298 12 18092 46 4200 80 1256 13 17257 47 4040 81 1216 14 16465 48 3887 82 1178 15 15714 49 3741 83 1141 16 15001 50 3601 84 1105 17 14325 51 3467 85 1071 18 13682 52 3339 86 1037 19 13073 53 3216 87 1005 20 12493 54 3098 88 974 21 11943 55 2985 89 945 22 11420 56 2877 90 916 23 10923 57 2773 91 888 24 10450 58 2674 92 862 25 10000 59 2579 93 836 26 9572 60 2487 94 811 27 9165 61 2399 95 787 28 8777 62 2315 96 764 29 8408 63 2234 97 741 30 8056 64 2157 98 720 31 7721 65 2082 99 699 32 7402 66 2011 33 7097 67 1942 Page 19 of 21 02 10 04 hv test doc rev A High Voltage Board Test Protocol Temperature Conversion Table Temp C Temp F Temp C Temp F Temp C Temp F 0 32 0 34 93 2 68 154 4 1 33 8 35 95 0 69 156 2 2 35 6 36 96 8 70 158 0 3 37 4 37 98 6 71 159 8 4 39 2 38 100 4 72 161 6 5 41 0 39 102 2 73 163 4 6 42 8 40 104 0 74 165 2 7 44 6 41 105 8 75 167 0 8 46 4 42 107 6 76 168 8 9 48 2 43 109 4 170 6 10 50 0 44 111 2 78 172 4 11 51 8 45 113 0 79 174 2 12 53 6 46 114 8 80 176 0 13 55 4 47 1
16. 30262 Nut Grn Yel Power Supply O O 3 Red to Motor Red 4 Brown ve Red 2 Grn Yel e bun 5 9 Black IO Black to Motor Black Explorer Base Assembly 541415 Sheet 9 of 10 Information contained in this document is the property of Corporation and may not be copied reproduced or distributed without the express written consent of CEM Corporation Wire Braid 162750 Socket Head Capscrew 6 BR197529 Small Vessel Mount 163330 Vessel Mount Ring 162765 Attenuator Cover 163335 Phillips Flat Head Screw 4 Bri99415 w Loctite BR199022 Attenuator Assembly Discover and Explorer Direct Pressure System 541450 Implemented June 18 2003 Information contained in this document is the property of Corporation and may not be copied reproduced or distributed without the express written consent of CEM FETE Corporation Pressure Gauge 163390 Brass Fitting 163380 Pressure Regulator 163385 Brass Fitting 163380 Plug Supplied with Pressure Regulator Pressure Regulator Assembly 541455 Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM FERES Corporation C 2 2 2 2 2 2 2 2 Pressure Interface Board 541470 Attenuator Assembly 541450 Sheet 1 of 2 Info
17. Open the pressure sensor assembly gripper fingers Install push the alignment calibration tool supplied with the Explorer automation module into the pressure sensor assembly d Locate Atten Drop attenuator drop in the Z axis information and click the associated GO button The pressure sensor assembly will lower and the alignment tool will enter the attenuator The alignment tool should be centered as it enters the attenuator If necessary carefully reposition the Explorer automation module so that the alignment tool is centered in the attenuator e Install and slightly tighten the two screws securing the left side of the Explorer automation module to the support plate 29 Absolute Move Increment 2000 JEx_Sys_Status 0 000000 SN 0 Clamp D 5 Ex Stopped End e 8 2003 9 19 55 AM Time f Locate the Absolute Move section of the screen Position the curser in the Increment box Using the computer keyboard enter 2000 Press ENTER g Install and slightly tighten the screw securing the right side of the Explorer automation module ara i Locate the Zero Axis information and select left mouse click the Y button j Locate Up in the Z Axis information and click the associated GO button to raise the pressure sensor assembly k Remove the alignment tool from the pressure sensor assembly l With the gripper fingers completely opened locate
18. 13305 03400138 38 01 N10 M erac ON SMSHLLVW MOLLVId 1 Mu NOLLVHOdHODO W39 101 STDLIIV 30 25 EE ED 19aroud 03501 38 NI 40 1551924 NO1123fONd 319Nv QiiHL mm sv 103 10 WS ONY SUIHLIVN NJ 7 7 G10 FXX 0 0 TX 031312395 3S1MU3HIO SS31Nn S32NYU3101 suni 7 e ALTOVINIIONIGHIE T WMS NLLOLONT MAIO gt VIVO NOI11234SN 53118915 HLIM WJJ 01 Q3111N3U VALLI OIUA NOJN 123213 38 01 38V NOILIIGSNI 312118V 15813 UOJ S1UVd 600 FXXX ST JIIVN3H2S W31S4S 38014 3 7530 40 1134084 IHL 1 SIHI Quvog SIXV X Q10N310 9394315 0 SIXV X D 02443215 2 SIXV X 9344315 SIXV A 9349315 SIXV Z 8348315 8 SIXV X 8384315 V SIXV X 9NIMVUO 031551 v 85621 23 080338 NOISIAJY WAS 3170 7338 Q310N SS31Nn S39NYH3101 WYINID Qquvog fido 8091 35 9349199 ONNOYI Sd 2INGOW AYINI YIMOd ZH 09 10 0G WA 0 2 022 1 1 09 JVA 021 uw e L 9 IN39 10 sseJdxe y Jo peonpoudai peidoo eq Aew pue uogesodiog W3 Jo Ajiedoud y si jueuunoop siuj uoneuuoju
19. BR128117 w Loctite Interlock BR19922 Activator Base Slide Assembly 162530 Nut 4 BR199450 Interlock Switch 4 317075 Interlock Switch Bracket 2 Screw 4 162535 BR196002 Cavity O Assembly Interlock Assembly Discover 908005 Sheet 6 of 9 Information contained in this document is the property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Corporation Screw 2 BR196439 Stirrer Cover 162620 Star Washer 2 BR198650 Screw BR128200 Stirrer Belt 162570 Setscrew Provided w IR Option IR Sensor 541035 Stirrer Motor Pulley 162715 Stirrer Motor Adapter 162720 Magnet Pocket 2 Center of Plate Stirring Magnet 2 162215 Pulley Stirrer Motor 314105 162450 Shorting Plate 2 Screw 4 162455 BR196102 Discover 908005 Sheet 7 of 9 C ia iin In z Information contained in this document is property of CEM Corporation and may Corporation not be copied reproduced or distributed without the express written consent of CEM POWER ENTRY MODULE THERMAL POWER SWITCH SWITCH BROWN 5 BROWN BLUE NW 3 a pi 4 ae BROWN Ne eur GREEN 2 4 5 6 Qu 7 9 68 BROWN 8 RIGHT SIDE INTERLOCKS INTERLOCKS 7
20. Phillips Fillister Head Screw 6 BR196080 Rail 163255 Lead Screw 163185 Lead Screw Bushing Lead Screw End with 163360 Longer Shaft at Bottom Phillips Truss Head Screw 2 BR199426 Pe pe Microswitch Through this Opening Gripper Stop Block Microswitch 119630 Phillips Pan Head Screw 2 BR199448 Z Axis Tower Assembly with Direct Pressure 541425 Sheet 2 of 2 Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM iS E Self Locking B Setscrew Note Orientation BR197132 f Fi of Fingers 163705 Gripper Support 163216 Socket Head Capscrew 4 Standoff BR196446 163500 Standoff w Loctite BR198899 BR199022 w Loctite BR199022 Pressure Phillips Truss Clamping Head Screw Bracket 3 BR128200 163835 2 w Loctite BR199022 Keps Nut 2 Pressure BR130261 Transducer Assembly 541124 Caution Needle protruding through bottom of pressure transducer assembly is very sharp Phillips Truss Head Screw 2 BR196014 Limit Switch 314129 Phillips Pan Head Screw 2 BR128200 Expandable w Loctite Braided BR19902
21. 1 into the Stage Position entry area d Click the Load Vessel button The rack will move into position over the attenuator port The Z axis arm will move down and the gripper fingers will grasp and lift the vial from rack position 1 The rack will move back into the home position The Z axis arm will them move down and position the vial into the attenuator port It will then move back into its home position e Click the Return Vessel button The pressure sensor assembly will lift the vial from the attenuator and return it to position 1 of the rack assembly f Observe the movement of the vial into the attenuator and into the rack ensuring that the vial is lifted properly by the gripper fingers and that the vial is centered as it enters the attenuator and rack position Refer to the previous instructions and make any necessary adjustments f Repeat steps c through f for position 6 and position 24 39 Create a method and perform a complete cycle test with vials in all 24 positions to ensure proper operation Component Replacement Infrared Sensor Assembly 1 10 1 Position the Discover System power switch in the off position and disconnect the power cord from the electrical source Facing the instrument position it on its left side Remove the stirrer cover 162620 by removing the screw BR128200 that secures the cover then slightly tilting the cover away from the screw tab and lifting it
22. 32 diode D17 An D17 Ca 0 45 0 65 V 33 D17 Ca D17 An OL gt 1V Page 16 of 21 02 10 04 hv test doc rev A High Voltage Board Test Protocol General Debug Guidelines for Mag Current Measurement If any of the diodes D14 D17 are bad the current feedback will likely be low in the CCC field on the display and the feedback value will not make it to the 720 level for 300 watts Since the feedback level that the microcontroller sees is low the timing to the high voltage transformer will be increased above normal in an effort to get this level to the 720 vlaue In contrast the DC milliammeter in series with the magnetron ground connection will be showing a level greater than 150 mA at 300 watts and will be heading toward 200 mA as the power level ramps up from the startup level of 40 watts to the final level of 300 watts The MAX secondary current detection will not automatically shut the unit down since the current path has a problem and the feedback level is reduced This is why the test operator keeps his attention on the current meter and is ready to abort the test by opening the door switch If any of the diodes D14 D17 are bad not open amp not shorted possibly a diode drop in the reverse direction R53 34 8K will be paralled and give a low resistance reading Trying to measure one of the diodes in reverse will give perhaps two diode drops gt 1V instead of OL Since this is a bridge connection without specia
23. cause error if exceeds 65 C Normal operation temperature is 40 45 C Status Byte 2 Bit coded status value e 0x80 New version power supply e 0 01 No Microwaves e 0x02 Start up Sequence OK Secondary Current displays secondary current feedback 300 watts 720 counts 150 watts 360 counts Status Byte 1 bit code status value e 0x8000 Earth Ground Missing Flag Eliminated from currect Software revision 07 28 04 e 0x4000 Thermal Overload Flag Attenuator Open e 0 2000 Minimum Secondary Current Error Flag 0x1000 Attenuator Closed 0 0800 Power Supply Runaway Flag 0x0400 Temperature Stuck Flag heat sink temperature did not change Removed from current software revision 07 28 04 0x0200 Low Control Error Flag 0x0100 Hi Control Error Flag 0x0080 Secondary Current Range Error Flag 0x0040 Temperature Recover Flag 0x0020 Open RTD Error Flag 0x0010 Shorted RTD Error Flag 0x0008 Communications Time out Flag 0x0004 High Voltage Error Flag 0x0002 Low Voltage Error Flag 0x0001 Filament On Flag Under normal operating conditions after powering the unit on all above readings should be as follows zm mM co p 1 2 3 4 1 00 1 00 1 00 4 11 200 200 200 200 0 0 0 000 000 000 000 000 110 220 000 110 220 22 24 C 22 24 C 22 24 C 29 45 00 00 00 02 000 010 000 010 000 010 720 360 4002 1000 4002 1001 1 Attenuator op
24. 162555 Attenuator Cover 162630 Attenuator Assembly Discover with Direct Pressure System 541125 Sheet 1 of 1 Information contained in this document is property of CEM Corporation and may Corporation not be copied reproduced or distributed without the express written consent of CEM Wire Braid 162750 Socket Head Capscrew 4 BR197529 Vessel Mount Ring 162815 40 ml Vessel Mount 162765 Recess Hole Socket Head Capscrew 2 BR197532 Attenuator Pin 162555 Attenuator Cover 162630 Attenuator Assembly Standard Open Vessel Discover 541130 Sheet 1 of 1 Information contained in this document is the property of CEM Corporation and may Corporation not be copied reproduced or distributed without the express written consent of CEM Wire Braid 162750 Socket Head Capscrew 6 BR197529 Small Vessel Mount 163330 Vessel Mount Ring 163660 Phillips Flat Head Screw 4 Br199415 w Loctite BR199022 Attenuator Cover 163337 Attenutor Assembly Discover with IntelliVent Pressure Systemj 541615 Sheet 1 of 1 ew Corporation Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Ram Assembly Transducer Cep Pressure Transducer ERIT Spacer M
25. ALIOIILLNGONO 3 Y 82005 SM3HLLVIA W39 ALavtnyy A3 NOLLVHOdHOO W33 404 SUN 40 30D MI 290904 ANY 208 ALIWYINIIONJAA JA T ONILVOIGNT GALWHANSS udindwo3 4 y 3080 31V0 QIAOYddY 9 nad 0381 38 N39 30 NOISSINBJA l V LYA NOLLDadSNI YI TddNS HLIM N32 OL 319Nv GHIHL 0392382 310 NAY uC N31LIM HOLYd 103233 38 OL 34Y NOII123dSNI JIDILYV 19813 803 51878 Aranassy uray 2 TS ON iam coo XXX GIO KK LOCOS ONISVHIYNG W39 0314193dS_JSIMYJH1O SSIINN SIONVYITOL 4403 2 LIVN3H2S N31SAS YIAOISIG 9830 0 JHL SI SNIMVHO SIAL 0310N 59370 S3ONVEJIOl TWH3N35 j AV1dSIQ YAUHILS 010 3105 j y Quvog NOLIOG Qnis QNO NIWA 9708 q TANDB QNnOND Sd AlddfS YIMOd 3 Aldd S ONIHOLIMS GNO ALIAYS ON IN WS 1910 AS 801 INON ZH 09 10 05 IVA 0pZ 022 10 ZH 09 OVA O21 x x EAE MS 3 0N0238 LV NOULINOWN V ONIMVUG AINSSI Y 10 2 11 6222 N23 Q4023U NOISIA1U WAS 3170 338 6 g L 9 v 4 IN39 10 u yum sseJdxe y Jo peonpoudei peidoo eq Aew pue 5 W39 Ayiadoid y si siy peurejuoo ial ELI nisl 1530030
26. Atten Grip attenuator grip and click the associated GO button The pressure sensor assembly will lower Close the gripper fingers to ensure that the fingers will clamp the attenuator at the same time The gripper fingers should be completely parallel vertically and horizontally If necessary carefully reposition the Explorer automation module so that the gripper fingers will be aligned m Locate Up in the Z Axis information and click the associated GO button to raise the pressure sensor assembly Note If necessary repeat the above steps to verify the automation module alignment n Complete the tightening of the two screws securing the left side of the Explorer automation module to the support plate o Locate the Absolute Move section of the screen Position the curser in the Increment box Using the computer keyboard enter 2000 Press ENTER p Complete the tightening of the screw securing the right side of the Explorer automation module q Locate the Zero Axis information and select left mouse click the Y button Install the vessel racks into the tagble with the rounded ends toward the front of the instrument 30 In Out rack adjustment as follows 3l a Locate the vial position table in the lower right side of the Explorer Setup screen 1000 1 1850 2 2442 Ha 3 3033 3625 Suan c 6 4803 ABCD
27. BR196452 14 Green to COM Bearing 163170 Fully Enclosed Side Up Z Axis Tower Assembly with IntelliVent 541425 Sheet 2 of 3 Proximity Switch 119780 Switch Retainer 163280 Pan Head Screw 2 BR196018 Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Corporation Route Wiring Interlock thru Opening Switch Wire 12 of Wire Harness 119760 Phillips Pan Motor Wire 11 of Wire Head Scrw 4 BR199440 Assembly Harness 119760 Loctit 541460 ops BR199022 Coupling 163400 Motor Setscrew 2 Socket Head Bracket e BR197151 Capscrew 4 163165 BR196447 0 2 Phillips Fillister 5 6 0 BR196080 2 Rail Sensor 163255 Switch 2 e 163270 0 Fitting 2 0 Phillips Pan 163240 Head Screw 3 6 BR196015 27 Lead Screw 2 163185 0 Gripper 163225 b Anchor 3 109978 Lead Screw Bushing Lead Screw End with 163360 Longer Shaft at Bottom Wire Tie 3 Phillips BR109975 Pan Head Screw 2 BR196110 Z Axis Tower Assembly with IntelliVent 541425 Sheet 3 of 3 Information contained in this document is the property of CEM Corporation and ma
28. Head Screw Cover 2 828 199403 163140 Pressure 0 Bottom White 163140 e o Air Line Tubing 32 Grommet BR198909 BR189160 Phillips Flat Head Screw 3 Phillips Truss BR196079 Head Screw 2 Left Cover 163105 Top Black Air Line Tubing 32 Phillips Truss BR198901 Head Screw 2 BR128205 Phillips Truss Z Tower Head Screw 4 541425 AE 4 BR128205 163115 Socket Head Cable Capscrew 4 BR198817 BR196449 Phillips Truss w Loctite EY Head Screw 4 Rear Table Cover BR199022 D BR128205 163145 D RIT Anchor 3 o 109978 d De Ti o i Wire Tie 3 BR109975 Explorer Base Assembly 541415 Sheet 8 of 10 2 Corporation HH Information contained in this document is the property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Positioning Top Z Tower Table Switch Switch Bottom Z Tower Switch 781 e Oj 0 O S MES Tt COM Orange 43 Green 2 Orange 4 Green Power Entry Base Module Ground Stud 3 Blue Brown BEC Grn yel
29. Position In Out Left Right Position w 5 E 111111 Click the Read button to read the vial position information Wait until all data is displayed in the windows Select click the small circle for vial position A1 Select click ABCD Position In Out Locate Rack Grip in the Z Axis information and click the associated GO button The assembly will lower The gripper fingers should be centered on the lip of the rack position A 1 from an in out perspective If necessary adjust the position of the fingers by adjusting the value for position Al Highlight the current value and type the new value adjusting the value in increments of 10 10 to move the rack out or 10 to move the rack in Click the button in the table portion of the screen The fingers will move to the new position Continue adjusting the value in increments of 10 until the gripper fingers are centered on the lip of the rack If an adjustment was made to ABCD Position in A 1 enter that value into the ABCD Offset In Out and select left mouse click W to write the value to the instrument memory Verfiy Left Right rack adjustment as follows Locate the vial position table in the lower right side of the Explorer Setup screen Click the Read All button to read the vial position infomation Wait until all data is displayed in the windows Select
30. and 2 milliseconds The high voltage probe is 1000 1 5 Determine the test voltage for the board s to be tested 6 Set the voltage select switch located behind the small current meter appropriately 120V Up 230V Down This switch is only read when the AC power is switched on 7 Iftesting 230V boards connect to the supplied step up transformer Do not plug into the rear of the Discover unit at this time 8 Ensure that the AC power switch on the left rear of the Discover unit is on and the AC power switch on the right front is off down 9 Before connecting the DUT visually inspect the board to ensure that e all four 4 ofthe high voltage transformer leads are soldered to the board e the thermal pad under Q2 left end of heat sink is pink e Q2 value by board voltage 120V gt 1MBH30D 060 230V gt 1MB25D 120 Ensure that the D is in the part number e the thermal pad under Q4 center of heat sink is black 04 value by board voltage 120V gt 1MBHS50D 060 230V gt 1MB25D 120 Ensure that the D is in the part number C1 value by board voltage 120V gt 0 15 uf 230V gt 0 033uf U11 value by board voltage 120V gt IR2113 230V gt IR2213 the jumper wire is from PD1 to PGI R45 amp R46 are 10 ohms T4 mounting polarity See Assembly drawing 10 Connect the high voltage board to be tested a control cable b AC power c high voltage wire Ensure that the board clamp on the right side of the test fixture is secu
31. and into the groove of the stirrer plate 162455 Tighten the two screws BR196439 with star washers BR198650 securing the stirrer motor 314105 to the instrument base Test the belt tension by turning the stirrer plate manually If binding occurs or the stirrer plate does not turn freely slightly loosen one of the two screws securing the stirrer motor pulley assembly and move the assembly slightly forward Tighten the screw and recheck the belt tension Position the instrument upright on its base Install the top cover assembly 660929 and using the four 4 screws secure it to the base Install the Top Cover Lid 162710 by engaging the front insert tabs and sliding the lid forward until it stops Lower the lid to engage the secure tab at the rear center of the lid until it snaps into place Plug the power cord into the electrical outlet Position the on off switch in the on position Cooling Solenoid 1 2 10 12 13 14 15 16 17 Position the Discover System power switch in the off position and disconnect the power cord from the electrical source Remove the top cover lid 162710 by pressing lightly on the secure tab at the rear center of the lid while slightly lifting and pulling backward on the lid to disengage the front insert tabs Remove the four 4 screws securing the top cover assembly 660929 Disconnect the cooling solenoid assembly P N 162550 from the solenoid wiring ha
32. be shorted If D3 checks OK it is OK whether or not Q4 had a problem If Q4 amp D3 both have to be replaced it is best to replace Q2 otherwise you may have to replace Q2 later and also Q4 D3 a second time If Q4 is faulty and D3 is OK and Q2 appears OK not replacing Q2 may be OK if Q2 were compromised it may not show up with the voltage levels of a Fluke meter but will when hundreds of volts come into play Check 011 When replacing parts mounted on the heat sink consult the mounting screw torque specifications provided on the assembly drawing Page 15 of 21 02 10 04 hv test doc rev A High Voltage Board Test Protocol Top Side Test Points and measurements D14 D17 plnout And Cathode Ca Cathode Anode A Fluke 87 True RMS meter was used for the following measurements Figure 9 Point to Point Correct Readings Incorrect Step Meter Function Red Black 20 ohms Q R53 1 R53 2 34 8KQ 1 lt 34 21 ohms 00 R53 2 R53 1 34 8KQ 1 34 22 ohms Q R1 1 R1 2 0 3 0 5 23 ohms Q R1 2 R1 1 0 3 0 5 24 ohms 00 R9 1 R9 2 0Q 10 Q 25 ohms Q R9 2 R9 1 00 100 26 diode 9M D14 An D14 Ca 0 45 0 65 V 27 diode D14 Ca D14 An OL gt 1V 28 D15 An D15 Ca 0 45 0 65 V 29 diode 9 D15 Ca D15 An OL gt 1V 30 diode D16 An D16 Ca 0 45 0 65 V 31 diode D16 Ca D16 An OL gt 1V
33. in the off position and disconnect the power cord from the electrical source Remove the top cover lid 162710 by pressing lightly on the secure tab at the rear center of the lid while slightly lifting and pulling backward on the lid to disengage the fronts insert tabs Remove the four 4 screws securing the top cover assembly 660929 Using an Allen wrench remove the two Allen screws securing the right interlock switch assembly to the top microwave choke plate Use extreme caution to prevent damage to the switch assembly wiring which is still connected to the assembly Slide the right interlock pin out of the microwave cavity choke plate assembly Remove the AC power connector from the high voltage power supply located on the front left corner of the top cover of the HV supply Using an Allen wrench remove the two Allen screws securing the communications connector located on the front right corner of the top of the HV Supply Remove the connector Using an 11 32 hex nut driver remove the grounding strap connecting the HVsupply cover to the top of the waveguide Using a Phillips screwdriver remove the four screws securing the HV supply to the instrument base Note Eight 8 screws are visible on the top of the HV supply The four 4 screws securing the supply to the base are located closest to the outside of the supply The 4 screws located toward the center of the supply secure the internal boards to the supply assembly and
34. left mouse click the small circle for vial position A1 Select left mouse click Left Right Position Locate Rack Grip in the Z Axis information and click the associated GO button The assembly will lower The gripper fingers should be centered on the lip of the rack position A 1 from a left right perspective If necessary adjust the position of the fingers by adjusting the value for position Al Highlight the current value and type the new value adjusting the value in increments of 10 10 to move the rack to the left or 10 to move the rack to the right Click the GO button in the table portion of the screen The fingers will move to the new position h Continue adjusting the value in increments of 10 until the gripper fingers are centered on the lip of the rack 1 If an adjustment was made to the Left Right Position in A 1 increase each rack position left right value by the same amount and press left mouse click W to write each value to the instrument memory j Repeat the above steps to verify the left right alignment of racks B C and D 32 Connect the air regulator to the user supplied air source clear compressed air or nitrogen NOTE The air supply must e capable of delivering 30 psi 33 Connect the 12 length of tubing supplied with the Explorer automation module getween the connector on the right side of the Discover module facing back of instrument and one of the two connectors on
35. outward to disengage the insert tabs securing the cover Using an Allen wrench loosen the setscrew securing the IR assembly sensor head 541035 to the microwave cavity RF stub Using a downward force pull the sensor head off of the RF stub The sensor head will remain connected to the IR assembly cable Reposition the Discover upright onto its base Remove the top cover lid 162710 by pressing lightly on the secure tab at the rear center of the lid while slightly lifting and pulling backward on the lid to disengage the fronts insert tabs Remove the four 4 screws securing the top cover assembly 660929 Remove the two 2 screws BR196077 securing the IR assembly 541035 to the base of the instrument Disconnect the IR assembly wiring from the CPU board by removing the 4 pin connector at the J6 location and the ground connector at the J4 location on the board Carefully feed the IR assembly cable up through the access hole in the bottom of instrument Remove the IR assembly wiring from the wiring harness bundle 12 13 14 15 16 17 18 19 20 21 22 27 Lift the IR assembly cable sensor head calibration box and wiring harness out of the instrument Carefully route the new IR assembly cable and sensor head gently through the access port in the base of the instrument Secure the IR assembly calibration box to the base with two screws Tighten the screws until snug Note To prevent compon
36. power supply when this waveform is seen Turn off AC power unplug the unit and disassemble the high voltage transformer to check for improper assembly See Ferrite Core Assembly Page 7 of 21 02 10 04 hv test doc rev A High Voltage Board Test Protocol Waveform with Slug and Gap Reversed in the Winding Leg at 300 watts Tak 25 0 5 3 754 Acqs Figure 4 This frame is made using an incorrectly assembled high voltage transformer The ferrite slug and the gap spacer are reversed in the winding leg Bad high voltage waveform at full power 300 watts Note the lack of a negative flat portion even as the power has ramped up to 300 watts Also the magnetron current level will likely continue to be zero or very low since there is not enough high voltage to cause the magnetron to conduct current If the magnetron were conducting current then the negative portion would be flat depicting the zenering action of a conducting magnetron ACTION Turn off the door switch to stop the power supply when this waveform is seen Turn off AC power unplug the unit and disassemble the high voltage transformer to check for improper assembly See Ferrite Core Assembly Page 8 of 21 02 10 04 hv test doc rev A High Voltage Board Test Protocol Waveform with Slug Missing in the Winding Leg at Startup Tak FINIS 25 0k5 s 3159 Acgs 2 00 Figure 5 This frame is made using an incorrectly assembled high voltage transformer The fer
37. screws provided with the Explorer automation module in the exposed screw hole Remove the screws and two white positioning braces from the Explorer automation module Reinstall the screws Discard the positioning braces Connect the 7 pin pressure sensor connector to the 7 pin electrical connector in the rear of the Discover module Connect the serial cable cream colored between the bottom bottom 9 pin male connector of the Explorer automation module and the right serial port comm port 2 of the Discover module facing back of instrument Place the computer on a suitable work area preferably on the right side of the instrument for ease of operation Connect the serial cable gray between the computer and the left serial port comm port 1 of the Discover module Plug the power cord of the Computer into the electrical outlet and boot the computer ensuring the operating system loads properly Connect the power cord to the Discover module and plug it into an appropriate electrical outlet Connect the power cord to the Explorer automation module and plug it into an appropriate electrical outlet Position the power switches of both the Discover module and the Explorer automation module in the position Using the keyboard on the Discover module press the EDIT key Press the right arrow key twi times The screen will display System Options Press the ENTER key The screen will display Peripheral Settings Press the ENTER k
38. the on position Discover System Specifications Electrical Requirements Safety Features Magnetron Frequency Power Output Magnetron Protection Microwave Cavity Dimensions Overall Weight Printer Port Computer Compatibility Internal Diagnostic Software Pressure Control System Temperature Control System Service Accessibility Patents 120 VAC 90 140 VAC 60 Hz 10A 120 VAC 220 240 VAC 202 250 VAC 50 Hz 15 240VAC Detachable Power Cord I E C and U L approved Variance in line voltage can affect microwave power output Three independent safety interlocks including interlock monitoring system plus two independent thermal switches used in each instrument to prevent instrument operation and microwave emissions in case of improper attenuator closure or misalignment Instrument complies with HHS standards under 21 CFR Part 1030 10 Subparts C 1 C 2 and C 3 2455 MHz 300 watts 10 Wave Guide Design Patent Pending to protect magnetron from reflected energy ensuring constant power output Heavy duty multi layer stainless steel 16 3 4 x 14 x 8 1 2 42 5 cm x 35 5 cm x 22 2 cm Dx Wx H 28 165 or 12 6 kg 25 Pin Epson and IBM Compatible 80C188 on board computer controls all system functions System can perform all functions with or without connection to external PC RS 232 9 Pin IBM PC compatible BITS System Built In Test System Checks monitors line voltage
39. the instrument while lifting it upward Install the new HV supply on the instrument base Connect the HV wires to the magnetron white wire on top tap black on bottom tap Connect the two ground straps to the waveguide tap Using an 11 32 hex nut driver tighten the hex nut Install the magnetron cooling fan cover and secure it with the two screws Connect the two wires extending from the CPU board to the magnetron cooling fan Connect the two wires extending from the CPU board to the HV supply cooling fan 21 22 23 24 25 26 27 Secure the HV supply to the instrument base by installing the four screws into HV supply cover Install the communications connector in the right front corner of the HV supply Install the two Allen screws to secure the connector Connect the AC power connector to the HV supply in the left front corner of the HV supply Install the right interlock pin into the choke plate assembly Install the right interlock switch assembly bracket to the top choke plate and secure it using the two Allen screws Install the right interlock switch assembly bracket to the top choke plate and secure it using the two Allen screws Ensure that the interlock switch is adjusted for proper engagement Take care to adjust the Interlock Switch for proper engagement Refer to procedures in this manual for interlock switch adjustment Plug the power cord into the electrical outlet Position the on off switch in
40. the manifold of the Explorer module 34 Connect the long length of tubing between the second connector on the manifold of the Explorer module and the air regulator 35 Set the air regulator to 30 psi 36 Verify the proper operation of the gripper finger switches as follows a Refer to the Absolute Move section of the Explorer Setup screen The Clamp configuration should read 3 with the gripper fingers opened Absolute Move Increment Ex Svs Status 4 111111 5H 0 3 5 Stopped End Now time End of Cycle Time b Manually close the gripper fingers The Clamp configuration should read 0 with the fingers closed c Manually place and hold a vial in the gripper fingers The Clamp configuration should read 2 while the vial is secure 37 Ensure that all three 3 screws securing the Explorer automation module to the support plate are tightened securely 38 Place vial in position 1 of the racks Verify that the pressure sensor assembly properly loads vials into the attenuator and returns vials to the racks as follows a Place vials in positions 1 6 and 24 of the racks Click the All button in the section of the Explorer Setup screen to ensure that all components move to their home positions b Locate the Vessel Control section in the lower left corner of the Explorer Setup screen T mmm c Using the keyboard type
41. the microwave cavity RF stub Using a downward force pull the sensor head off of the RF stub The sensor head will remain connected to the IR assembly cable Loosen the two screws BR196439 with star washers BR198650 that secure the stirrer motor 314105 to the instrument base Slide the stirrer motor pulley assembly forward permitting slack in the belt Carefully remove the loose belt from the groove of the stirrer plate 162455 Remove the stirrer motor belt Remove the two Allen screws 162715 securing the stirrer motor pulley to the stirrer motor adapter 134720 and remove the stirrer motor pulley Remove the top cover lid 162710 by pressing lightly on the secure tab at the rear center of the lid while slightly lifting and pulling backward on the lid to disengage the fronts insert tabs Remove the four 4 screws securing the top cover assembly 660929 Disconnect the stirrer motor assembly from the CPU board by disconnecting the 2 pin connector at pin location J8 Remove the stirrer motor wiring from the wiring harness Position the instrument upright on its base Remove the stirrer motor Position the new stirrer motor assembly through the access in the instrument base Reposition the instrument upright on its base and loosely install the screws and star washers Install the stirrer motor pulley onto the stirrer motor adapter and secue it with two Allen screws Position the belt around the stirrer motor pulley assembly
42. 119780 163140 Lead Screw Nut 163200 7 Pan Head Screw 2 BR196018 Retainer Plate 163205 Nut Mounting Plate 163195 Phillips Pan Head Screw 2 BR196117 Din Connector w Loctite BR199022 Explorer 2 Axis with IntelliVent Pressure Sensor 541610 Sheet 4 of 4 Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Spacer Pressure Transducer Finger iB N Spring N CR al NES an 20 Ummm TT aaa Per Finger Spring BR198002 Finger 4 163740 Bearing 163675 Transducer Cap 163765 Pressure Transducer 119765 Transducer Spacer 163815 pp p gt Sensor Body 163710 Finger 163720 Super Lube BR199188 E ring BR199166 Explorer IntelliVent Pressure Module 541650 Sheet 1 of 2 Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Phillips Pan Head Screw 3 BR196450 Socket Head Capscrew 2 BR197528 Motor Mount 163735 Switch f Lever Spring Pin S 163730 BR198009 Spring 2 BR198010 Motor Gear Motor Assembly 119770 541655 Vessel In Position
43. 16 6 81 177 8 14 57 2 48 118 4 82 179 6 15 59 0 49 120 2 83 181 4 16 60 8 50 122 0 84 183 2 17 62 6 51 123 8 85 185 0 18 64 4 52 125 6 86 186 8 19 66 2 53 127 4 87 188 6 20 68 0 54 129 2 88 190 4 21 69 8 55 131 0 89 192 2 22 71 6 56 132 8 90 194 0 23 73 4 57 134 6 91 195 8 24 75 2 58 136 4 92 197 6 25 77 0 59 138 2 93 199 4 26 78 8 60 140 0 94 201 2 27 80 6 61 141 8 95 203 0 28 82 4 62 143 6 96 204 8 29 84 2 63 145 4 97 206 6 30 86 0 64 147 2 98 208 4 31 87 8 65 149 0 99 210 2 32 89 6 66 150 8 33 91 4 67 152 6 Page 20 of 21 02 10 04 hv test doc rev A High Voltage Board Test Protocol Revisions 01 09 04 Step 10 amp 11 changed on Page 14 Bottom Side Test Points and Measurements Add revisions to TOC Page 21 of 21 02 10 04 hv test doc rev A Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM FERES Corporation C Screw 2 BR196109 2 Screw Screw 4 BR196279 BR128211 Foot 4 Base 134666 162600 Screw 2 BR196111 Top Cover Assembly 660929 Screw 4 BR196435 Display Cable 541150 Anchor 113730 Display Spacer 162780 CPU Board 541160RA Top Cover Lid Plug 162710 BR199061 Keypad 162515 ES Top Cover 162605 e Jackscrew 4 Screw 8 199087 BR128200 Screw 3 Power BR196431 Supply Switcher 317050 Dis
44. 2 Keps Nut 2 Sleeving BR199450 BR198862 3 Piece Wire Fitting Phillips Truss Wire 163355 Head Screw Fitting Nut BR128205 should be tight enough not to spin when larger nut is tightened Pressure Cover 163140 Wire Clamp BR109976 Screw BR199403 EM M _ From Pressure Module Green gt Brown E Match Colors gt Blac TP White c Tp Back io From Belden Cable Match Colors Pressure Interface Keep Twisted Board 541470 Pairs Together Z Axis Tower Assembly with IntelliVent 541425 Sheet 1 of 3 gt Corporation Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Thumb Screw 4 Gripper Support 163216 Gripper Finger 163230 Gripper Finger 163235 Fillister Head Screw BR196080 Lead Screw Magnet Retainer 163275 Spring BR198012 Phillips Pan Head Screw BR199422 Proximity Magnet Nut Phillips 163200 219780 Pan Head Screw 2 BR196117 w Loctite BR199022 y os Phillips Pan Head Screw 2 BR196018 Retainer Plate 163205 Nut Mounting Plate 163195 Phillips Truss Head Screw 2 owes BR199426 Support 163160 N Microswitch 119630 Gripper Stop Block 163175 Phillips Pan Head Screw 2
45. 3 Capscrew 2 BR197551 Interface Board 541620 Wire Fitting 163780 Phillips Pan Head Screw 4 BR128205 Cover 163845 Nut 163780 White Black Din Connector Discover IntelliVent Pressure Module 541660 Sheet 3 of 4 Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Se 2 7 Corporation el Pink Whit ms Ol se Pressure Module WHT Ol Green fan Ol Yellow 2 Coble BRISB099 32 Wire Red from Belden Coble Ni ronge from Sw Pos 1 Gray from Switch Wire Tie BR109975 Resistor 312711 Orange 3 ray 3 with Resistor ray l Orange l Black Board Green Board Yellow Board Red Solder to Solid Wire with ORG 1 and GRY 3 Violet Solder to Gray 1 Brown Solder to Black Motor Blue Solder to Red Motor White Solder to Orange 3 Belden Cable Discover IntelliVent Pressure Module 541660 Sheet 4 of 4 J9 31V2S ONIMV3Q 1530038 01 SSII 7 1339 IWS 3800138 38 OL ONIAVUC CUL Lonny x
46. 4 6 g L 9 y 2 IN39 Jo 1uesuoo USM ss sdx y 10 peonpoudei peidoo eq uoneJodio Aew pue 5 W39 Ayiadoid y si sly peurejuoo uoneuuoju diin pass shiste I M m moon Sitch D i 53 H in 1 a i EDI Ds LH uris d nnn T T j Lats 0 ut um
47. 99022 BR199022 Limit Switch 314129 Caution Needle protruding through LAS bottom of pressure transducer assembly is very sharp Keps Nut 2 BR199450 Phillips Pan Head Screw BR199440 w Loctite BR199022 Self Locking Setscrew BR197132 Nut Mounting Plate 163195 Pressure Transducer Plate Assembly Phillips Pan 541122 163205 Head Screw 2 BR128210 w Loctite BR199022 Retainer Tower Assembly with Direct Pressure 541425 Sheet 1 of 2 Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Motor Assembly 541460 Socket Head Capscrew 4 BR196447 Motor Bracket 163165 Phillips Pan Head Screw 3 BR196015 Gripper Bracket 163220 Sensor Switch 2 163270 Fitting 2 163240 Angular Gripper 163225 Phillips Pan Head Screw 4 BR196012 Gripper Gripper Finger 163235 Microswitch 119630 14 Green to COM Finger 163230 Tower Support 163160 M 163170 Fully Enclosed Side Up 163175 Route Wiring Interlock thru Opening Switch Wire 12 of Wire Harness 119760 Wire 11 of Wire Harness 119760 Phillips Pan Head Scrw 4 BR199440 w Loctite BR199022 Coupling 163400 Setscrew 2 BR197151
48. Aligning Choke Lid with Cavity Orient Choke Plate as Shown Align Notches Align Notches Discover 908005 Sheet 4 of 9 Information contained in this document is property of CEM Corporation and may Corporation not be copied reproduced or distributed without the express written consent of CEM Screw 6 BR128212 Locking Ring Spacer 2 g __ 162805 e i Orient with e Wide Cutout on Bottom Half moon Shape on Locking Ring Should Align with Interlock Mounting Holes On Plate IR Cover w o IR 162800 Bearing Stirrer 3 Nylok Nut 3 162440 BR199451 Ball Bearing 3 Setscrew 162445 w o IR BR199085 Cavity Assembly Cavity Elbow Sealer 162520 Magnetron 111280 Magnetron Thermal Switch 142020 Screw 2 BR128123 Keps Nut 4 BR198151 Discover 908005 Sheet 5 of 9 Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Corporation Locking Ring Assembly 541130 eed Screw 2 BR197536 162425 w Loctite BR199022 Screw 2 BR197536 w Loctite BR199022 Interlock Activator Slide 162530 Screw 4
49. BR128200 w Loctite BR199022 Anti Backlash Nut Lock 163150 Anti Backlash Nut Bracket 163155 Lead Screw 163080 Flat Washer BR199189 phillips pan Head Screw 2 BR199422 w Loctite Lead Screw e Mounting Block 163130 Rail w Stops 2 163070 Socket Head Capscrew 4 BR196442 Explorer Base Assembly 541415 Sheet 3 of 10 Note Position race of rail against dowel pins for alignment Information contained in this document is the property of CEM Corporation and may Corporation not be copied reproduced or distributed without the express written consent of CEM Leveling Block 4 163370 Pan Head Screw 8 Slide 4 BR196431 163100 w Loctite BR199022 2 4 Slide Assembly 163090 Slide Assembly 4 Capscrew 2 BR196444 Capscrew 16 BR196446 Pan Head Screw 2 BR128200 w Loctite gt BR199022 SS ae BR196442 163033 End Plate Assembly 163065 Phillips Flat Head Screw 12 BR196054 Positioning Table E pauses Vessel Rack Base End Plate Bearing 2 163030 Assembly 163070 163065 Bearing Race 2 SS 163070 Rack Base NS IN X Rack Base 163031 Rack Base 163032 Explorer Base Assembly 541415 Sheet 4 of10 Information contained in this document is propert
50. Calibrated Power Supply Low Voltage Power Supply High Voltage Power Supply Comm Timeout Power Supply Shorted RTD Power Supply Open RTD Power Supply Temperature Power Supply Sec Max Range Power Supply Hi Control Power Supply Lo Control Power Supply Delta Temp Power Supply RunAway Power Supply PS Comm Failure Power Supply PS Not OFF Power Supply Sec Min Range Power Supply Thermal Overload Power Supply Ground Error Power Supply No Microwaves Pressure Drop Error Temperature Drop Error No Pressure Error Excess Pressure Error Fiber Optic Timeout Error Fiber Optic Probe Failure Explorer Module Vessel Missing Vessel Dropped Vessel Stuck Time out Missed Z Axis Limit Switch Bad Start Location Low Air Display is not functioning A D is not functioning Temperature Device has not been calibrated Pressure Device has not been calibrated Line Voltage Below minimum level Line Voltage Above maximum level Power Supply Lost communication with Discover RTD in Power Supply is shorted RTD in Power Supply is open Power Supply Heat Sink temperature too high 65 C Secondary Current in Power Supply too high Power Supply unable to generate enough power Power Supply unable to generating too much power No temperature rise detected in Heat Sink Power Supply could not adjust to required power Discover lost communication with Power Supply Power Supply is applying power when should be off Seco
51. SLYVd 600 FXXX 7910 0 0 FX CE7 031312398 3 SSIINN S32NYU3101 Q310N SSJINN S3ONVHU3101 IVYINI9 Q NMOUG 3178 Xov 1g 43349 MO114K 0 L 6 9NIMVUO 0301551 09161 N23 Qu023MH NOISIA3H 038 LIIOIA YOLOW 3LIHM YIONGSNVYL 300155309 eI aay 01021 7102 S 11 0281 JOTZA ds 44 G 2s HILIMS NOILISOd NI 15 138534 HOLIMS 035012 N340 IN39 10 sseJdxe y Jo peonpoudai peidoo eq Aew uogesodiog W3 Jo Ayedoid y si jueuunoop sly 05 _ LN 30 OL cero IE u ADU auus t NoLLVuOdUOS in mer MIN E ELLA PUR T MEAM ALIO GM X095 SNILYDION JML 14301 S04 ANY 01 T Y 120 0381 304 30 MOISSINE viv C NOLLD3dSNI_ UII Idd NS HLIM N32 OL 03111938 mA Minn QR MD 38 OL JUV NOI12345NI 319114 15813 303 51874 xx PC S00 FXXX G10 XY OEO FE GF gt 18040 03131234 3S1Mu3HIO SS31Nn S32NYH3101 JIIVN3H2S N31SAS u3u01dXi 2530 Luva 40 1134084 JH 1 SII SIHI Q310N SS31Nn 32NYH3101 YH3N3D Quvog SIXV 0103105 uly 9394315 0 SIXV X ur YOSNAS 388149 8389315 SIXV A 9344315 2 SIXV X 932443215 8 SIXV X
52. U28 Ho JIG DISPLAY __ RIBBON 1 o 0 mo mp 4 LLL C O a SERET um JL Hi mul E 1 oo fre 1 ate adel _ ER O 4 546 JT s DC POWER 20 TO 23 M FLOW VALVE IR GND SOLENOID 32 33 IR 57 TO 60 INT SW 15 16 STIRRER MIR 30 31 Battery 3V Lithium or Equivalent Discover 908005 Sheet 9A of 9 Information contained in this document is the property of CEM Corporation and may not FETE Corporation be copied reproduced or distributed without the express written consent of CEM E Ring BR198872 Needle Seal Transducer 162670 Assembly Retainer Transducer 314286 Caution Needle is very sharp RED TWISTED WITH BLACK TWISTED BLACK WITH RED WHITE TWISTED WITH BLACK BLACK TWISTED WITH WHITE White green Black white Wiring Diagrams EEF O ring 162160 Black blue Red red Groove Transducer Housing 162692 y Roll Pin 162680 Transducer Housing 162692 Needle Screw 162861 Note Torque needle screw to 18 in Ibs Needle 162676 Discover Pressure Transducer Assembly w Non Removable Needle 541121 Sheet 1 of 2 OBSOLETE HE Information contained in this document is the property of CEM Corporation and may gt Corporation not be copied reproduced distributed without the express written consent of CEM Caution Needle protruding t
53. akage Check leakage around the cavity lid Chi aN NOTE CEM does not recommend use of meters available in electronics stores because they are prone to give erroneous read ings and lack the necessary sensitivity to properly test an instrument for microwave leakage The U S Government defines excessive microwave leakage as 5 If the instrument shows excessive microwave leakage do not attempt further operation Contact the CEM Corporation Service Department or the local CEM subsidiary or distributor for further instructions Microwave Power Measurement Use the following procedure to determine actual power output in watts for a 300 watt setting wy ee 59907 LSS 11 12 13 Remove the 10mL attenuator access port Place the Teflon spacer on the floor of the cavity Create a power and time method using 300 watts of power and a run time of 60 seconds Place 100 mL of ambient temperature 18 22 C deionized water and a stirring bar if available in a 100 mL round bottom flask with a ground glass joint of a size less than or equal to 24 40 Using a thermometer with 0 1 C gradations Stir the water for at least 15 seconds then measure and record the initial water temperature T Ensure that the thermometer is immersed to its indicated immersion line prior to reading the temperature Remove the thermometer from the flask Carefully place the flask into the cavity Attach the attenuator with RF stub to accept a 24 40 g
54. attage selected Interlock s not properly adjusted or faulty Faulty controller board Faulty thermal switch Faulty high voltage component Low line voltage Incorrect wattage selected Faulty high voltage relay s Faulty high voltage component Interlock s not properly adjusted Faulty interlock s Low line voltage Faulty high voltage component Faulty DC power supply Faulty controller board Faulty continuous power supply No Display Loose or broken wiring connections Loose or faulty interface cable Faulty display Faulty controller board Inoperative Keyboard Inoperative Vessel Stirring Motor Erratic Pressure Erratic Temperature Loose or faulty interface cable Faulty keyboard Faulty controller board Microwave Leakage No Rise in Temperature Loose or broken stirring motor belt Faulty stirring motor Loose connector on controller board Incorrect A D setting Leakage from vessel Loose connector Improper grounding connection Faulty load cell Faulty pressure transducer Blocked or faulty needle Lens blocked Faulty IR sensor Faulty controller board Damaged attenuator Pressure sensor unattached or faulty Sample does not absorb microwave energy Faulty infrared temperature sensor Incorrect temperature calibration constants entered Lens blocked Error Messages Discover Module Display Error A D Error Temperature Not Calibrated Pressure Not
55. cover 908005 Sheet 1 of 9 Information contained in this document is property of CEM Corporation and may Corporation not be copied reproduced or distributed without the express written consent of CEM Display Cable 541171 Anchor 3 109978 CPU Board 541290RA Panasonic Battery BR2016 3V Lithium or Equivalent E PROM Discover 908005 Sheet 1A of 9 Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM 52 227 Corporation Power Power Switch Entry Mount Module 162525 Fuse 2 Power 119093 Switch 142000 BR188270 120V F 104 250V BR188280 240V F 5A 250V Knurl Head Screw BR198828 Spill Tray 541095 Screw 2 BR196013 Pressure Faston Plug BR109931 Air Line Fitting 256400 Swagelock Fitting 272407 Screw 3 BR128200 Pressure Solenoid Wires 32 amp 33 of Main Cover Wiring Harness amp Tubing 162615 Feed Through Opening Tubing 18 221220 Discover 908005 Sheet 2 of 9 Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Corporation wi putt an Kep Nut BR198151 Discover 908005 Sheet of 9 EEE Informa
56. dard Pressure Device 3500 Pneumatic locking pressure device 3100 Intelli vent Sensor with VIP switch actuated 2500 Intelli vent Pressure Sensor 2000 80 ml vessel option 1500 unassigned 1000 unassigned 0500 unassigned 0000 No pressure device connected CH2 Raw Pressure Reading CH3 SPARE not used at this time CH4 SPARE not used at this time CH5 SPARE not used at this time CH6 Raw IR Hi Range approx 1 count 190 CH7 Raw Low Range approx 10 count 1 C Access Code 123 200 NOTE If the unit resets to the power test rather than accessing the debug screen it is not communicating with the high voltage power supply This is typically indicative of a bad high voltage assembly The above screen is the high voltage power supply debug screen A B Power Table index displays which table entry is currently in use Ramp counter decreases from 200 until power delivered is within the required range then will reset to 200 Should not fall below 100 Ramp Done Flag will be set to 1 when power supply ramps to desired power level Runaway Counter will be incremented each time the power supply is unable to reach desired power in the prescribed time If 5 is reached an error will occur Line Voltage measured input line voltage Not calibrated Will read zero if interlocks are open Heat sink temperature measured temperature of power supply heat sink Will
57. eft side Remove the stirrer cover 162620 by removing the screw BR128200 that secures the cover then slightly tilting the cover away from the screw tab and lifting it outward to disengage the insert tabs securing the cover Using a wrench disconnect the fitting on the cooling gas inlet tubing and remove the tubing from the cavity assembly Using an Allen wrench loosen the setscrew securing the IR assembly sensor head 541035 to the microwave cavity RF stub Using a downward force pull the sensor head off of the RF stub The sensor head will remain connected to the IR assembly cable Loosen the two screws BR196439 with star washers BR198650 that secure the stirrer motor 314105 to the instrument base Slide the stirrer motor pulley assembly forward permitting slack in the belt Carefully remove the loose belt from the groove of the stirrer plate 162455 Remove the stirrer motor belt Position the new belt around the stirrer motor pulley assembly and into the groove of the stirrer plate 162455 Move the stirrer motor pulley assembly backward with steady even pressure until the belt feels tight Tighten the two screws BR196439 with star washers BR198650 securing the stirrer motor 314105 to the instrument base Test the belt tension by turning the stirrer plate manually If binding occurs or the stirrer plate does not turn freely slightly loosen one of the two screws securing the stirrer motor pulley assembly and move the asse
58. en with no microwaves present 2 Attenuator closed with no microwaves present 3 Attenuator open attempting to Microwave 4 Attenuator closed producing microwaves HIGH VOLTAGE TEST PROTOCOL High Voltage Board Test Protocol This document can be printed in color TABLE OF CONTENTS UOI DTE O 3 GOOD WAVEFORM AT STARTUD eese eese testen sten sten seta sets stes sens sens enne ense suse ense tassa sen 5 GOOD WAVEFORM AT 300 WATTSS eee eese eee eese en sete sensns natuss tn setas tasa ease tasto 6 WAVEFORM WITH SLUG AND GAP REVERSED IN THE WINDING LEG AT STARTUP 7 WAVEFORM WITH SLUG AND GAP REVERSED IN THE WINDING LEG AT 300 WATTS 8 WAVEFORM WITH SLUG MISSING IN THE WINDING LEG AT STARTUP reset ettet ntnnne 9 FERRITE CORE ASSEMBLY 10 DEBUG DISPLAY DATA MSY 11 BIT ASSIGNMENTS FOR ERROR FLAG BYTE 0 ccsscssssssssssssessssnsssssssscssscsssesseessssssesssssscsssesssnsesnsesseees 12 BIT ASSIGNMENTS FOR ERROR FLAG BYTE 1 ccscsssssssssssssscssesssssssssesscsssesssssesssesssesessscsssnsesnsesseees 12 BIT ASSIGNMENTS FOR ERROR FLAG BYTE 2 cssscsssssssssesssssenssssssssesseesssesssssssssessssssssecsscnsesnsesseees 12 HIGH VOLTAGE AREAS ON THE BOARD uu csscssscssscssscscessssssssecss
59. ent damage do not overtighten the screws Route the IR assembly wiring harness to the CPU board and connect the 4 pin connector at the J6 location and the ground connector at the J4 pin location Facing the instrument position it on its left side Using steady gentle pressure install the IR assembly sensor head onto the RF stub until it stops Using an Allen wrench tighten the setscrew Note Do not overtighten the setscrew Install the new stirrer cover 162620 by tilting it slightly away from the screw tab engaging the insert tabs and then sliding it in until it stops Install the screw that secures the cover BR128200 and tighten it until it is snug Position the instrument upright on its base Install the top cover assembly 660929 and using the four 4 screws secure it to the base Install the Top Cover Lid 162710 by engaging the front insert tabs and sliding the lid forward until it stops Lower the lid to engage the secure tab at the rear center of the lid until it snaps into place Plug the power cord into the electrical outlet Position the on off switch in the on position Calibrate the IR assembly using the calibration procedures outlined in this manual Stirrer Motor Belt 10 11 12 13 14 15 16 17 18 19 Position the Discover System power switch in the off position and disconnect the power cord from the electrical source Facing the instrument position it on its l
60. esssessesssenesensessesssssseessensecssecseseseessesssoes 13 BOTTOM SIDE TEST POINTS AND MEASUREMENTS ccsssssscsssssssssssessnssensessesssesecsssssssssscsssssesssesssees 14 GENERAL DEBUG GUIDELINES FOR POWER TRANSISTORS sscssssssssssessssssscsenssessesscssecsssessenseeee 15 TOP SIDE TEST POINTS AND MEASUREMENTS sscsscsssssscsscsssesssessssssenssenssssessssesesssesseesssesssessssseseees 16 GENERAL DEBUG GUIDELINES FOR MAG CURRENT MEASUREMENT cscsssssssssssessssssssssesesesesees 17 HIGH VOLTAGE WILL NOT START OR RUN DUE TO ERROR eerie eene 18 THERMISTOR TEMPERATURE VS RESISTANCE TABLE eese eene 19 TEMPERATURE CONVERSION TABLE eere eee eene enne tasa tastes ense ta sen 20 DAR AIL C 21 Page 2 of 21 02 10 04 test doc rev A High Voltage Board Test Protocol TEST PROCEDURE 1 Always wear safety glasses when testing 2 Study the accompanying Figures 1 thru 5 to become familiar with the possible high voltage waveforms to be encountered during the testing of the high voltage boards Read the test procedure completely prior to any testing 3 Study Figure 6 to become aware of the high voltages that are present on the board 4 Connect the high voltage probe connector box to an oscilloscope using the supplied BNC connector lock ring Set the scope for 2 volts div
61. ey Press the right arrow key two times The screen will display Mode Explorer Press the ENTER key Press the HOME key The screen will display Explorer Double click the Discover icon on the computer screen The instrument software requires a user name Once the User Name screen appears use the keyboard and type cem as the user name Do not enter a password at this time The Instrument Setup will be displayed on the Computer screen followed by the Automation Setup screen ur Ideas x Password Cancel Productivity a CEM Corporation www cemsynthesis com 704 821 7015 800 726 3331 ChemDrive Part Number 908100 2 From the Automation Setup screen highlight Instrument and select Explorer Setup iw Explorer Setup ial xl r Home Memory Zero Axis Z Axis ger eel el spi ool Address al Rack Grip 8800 wi 00 Data HE cj Atten Drop 22200 wi 50 Increment cz mm w ABCD Offset In Dut RN zm Ai Ed Bock 22000 w so m Absolute Move EE Buo Ce Dew C Em orie zoos 011 AM E EM LM LL E Vessel Control essel Contr c E E peun 2033 mm ___ C essel aa cT A vp E Stage Position 1 24 or 0 for 5 7 c direct up and down 6 usos C c c 1 1 L LN LE LEN
62. he following settings IR Emissivity E 75 IR Transmissivity T 70 Pressure Calibration NOTE If a new E PROM is installed the pressure calibration data must be re entered into the system setup information If the calibration data is not known calibration is required From the main menu press EDIT Use the arrow keys to toggle and select Pressure Press ENTER Enter Previous Calibration Values 4 Use the arrow key s and select Enter Calibration Press ENTER Press EDIT to highlight the slope calibration data Using the numeric keypad enter the previous value for the slope of the pressure curve Press ENTER The instrument highlights the intercept data Using the numeric keypad enter the previous value for the intercept of the pressure curve Press the ENTER key NOTE If a new temperature sensor or cavity liner is installed calibration of the temperature sensor is required Calibrate Pressure Sensor 18 Use the arrow key s and select Calibrate Device Press ENTER Upon the Zero Pressure prompt ensure that there is no pressure applied to the pressure assembly Press ENTER Upon the Apply Pressure prompt apply a pressure source with a known pressure value to the pressure sensor assembly maximum pressure 300 psi or 21 bar Using the numeric keys enter the applied pressure value Press ENTER Press HOME to return to the main menu Explorer Module Assembly 1 2 10
63. he negative flat portion will increase as the waveform ON timing is increased This is apparent in figure 2 Page 5 of 21 02 10 04 test doc rev A High Voltage Board Test Protocol Good Waveform at 300 Watts Tok 00 25 0k5 s 129 Acgs Figure 2 This frame is made using a correctly assembled high voltage transformer Good high voltage waveform at full power 300 watts in this case The increased width of the negative flat portion is representative of the full waveform timing used to achieve full power The changing width can be seen as the power ramps up from the startup power of 40 watts Figure 1 to the full power of 300 watts Page 6 of 21 02 10 04 hv test doc rev A High Voltage Board Test Protocol Waveform with Slug and Gap Reversed in the Winding Leg at Startup BEGG 25 0 5 5 121 Acqs 3 94 3 584 Figure 3 This frame is made using an incorrectly assembled high voltage transformer The ferrite slug and the gap spacer are reversed in the winding leg Bad high voltage waveform at startup This waveform appears as the high voltage starts up Note the lack of the negative flat portion as seen in Figure 1 As the power ramps up to 300 watts the negative flat portion will not occur This is apparent in Figure 4 Also the magnetron current level will likely be zero or very low since there is not enough high voltage to cause the magnetron to conduct current ACTION Turn off the door switch to stop the
64. he temperature sensor as outlined in the System Setup section of this manual Cavity Liner Spill Tray Cleaning WARNING Proper precautions must be taken to avoid contact with solvents or solvent vapors Protective gear should be worn as outlined in the user s safety program for hazardous materials and the reagent manufacturer s material safety data sheet Refer to these guidelines for proper handling and disposal of reagents Remove the screw securing the spill tray to the back of the instrument cover Carefully slide the spill tray out of the instrument Properly dispose of the contents of the tray Rinse the tray with an appropriate solvent Install the spill tray and secure it to the instrument with the screw Spill Tray Adjustment of Interlock Switches 1 2 Place the attenuator inside the instrument cavity and rotate it clockwise Loosen the screws securing the interlock switches Press the left bracket against the attenuator until both switches of the left interlock are engaged Tighten the screws to secure the left bracket ensuring that the bracket remains atand ush to the instrument cavity Do not overtighten the bracket to prevent bending of the bracket Perform steps 3 and 4 for the right side bracket Remove the attenuator from the instrument cavity by rotating it counterclockwise Temperature Calibration NOTE If a new E PROM is installed the temperature calibration data must be re entered into the s
65. hrough bottom of assembly is very sharp Screw 2 Cover 162643 Latch Button Transducer 162655 Assembly Screw 2 162695 Loctite 242 Groove must align BR199022 with screw hole j Spring BR198873 Pressure Transducer 1 Pressure 162637 Transducer Finger 162646 Spring Latch BR198809 Bushing 162650 Retainer Screw 2 Phillips 162695 N Truss Head w Loctite y Q Screw 4 BR199022 BR196011 w Loctite an BR199022 Finger 162660 Discover Pressure Transducer Assembly w Non Removable Needle 541121 Sheet 2 of 2 OBSOLETE Information contained in this document is the property of CEM Corporation and may not FETE Corporation be copied reproduced or distributed without the express written consent of CEM E Ring BR198872 Needle Seal Transducer 162670 Assembly Retainer Transducer 314286 Caution Needle is very sharp RED TWISTED WITH BLACK TWISTED BLACK WITH RED WHITE TWISTED WITH BLACK BLACK TWISTED WITH WHITE White green Black white Wiring Diagrams EEF O ring 162160 Black blue Red red Groove Transducer Housing 162692 Roll Pin 162680 Transducer Housing 162692 Needle Screw 162861 Note Torque needle Needle screw to 18 in lbs 162676 Discover Direct Pressure Transducer Asse
66. in all windows 27 Locate Atten Grip attenuator grip and click the associated GO button The pressure sensor assembly will lower 28 Align the explorer module as outlined below IntelliVent Note Proceed to the next page for alignment if instrument is equipped with direct pressure a Using minimal force close the gripper fingers If necessary adjust the position of the Explorer automation module so that the gripper fingers are centered around the port of the attenuator and reach the attenuator simultaneously b Locate Up in the Z Axis information and click the associated GO button to raise the pressure sensor assembly Open the pressure sensor assembly gripper fingers Install push the alignment calibration tool supplied with the Explorer automation module into the pressure sensor assembly d Install and tighten the two screws securing the left side of the Explorer automation module to the support plate Absolute Move Increment 2000 Ex Sys Status 0 000000 SN 0 Clamp 05 Ex Stopped End jen 8 2003 9 19 55 Time e Locate the Absolute Move section of the screen Select left mouse click the Y axis Position the curser in the Increment box Using the computer keyboard enter 2000 Press ENTER e Locate the Absolute Move section of the screen Select left mouse click the Y axis Position the curser in the Increment box Using the co
67. ire BR199222 Wire Tie BR109975 2 m 5 Pressure e Interface OOOH Board ud 541475 Nos Jof Wire Tie BR109971 Wires BR199220 Los Pressure Assembly 541650 Explorer Z Axis with IntelliVent Pressure Sensor 541610 Sheet 1 of 4 Corporation Information contained in this document is the property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Half Above Half Below Sensor Switch 2 163270 Phillips _ Pan Head Y Screw 3 BR196015 163236 Self Locking Setscrew BR197132 Block 163255 Phillips Socket Head Screw 4 BR196446 Gripper Support 163216 Pan Head Screw BR199422 Gripper Bracket 163221 White Tubing Fitting 2 163240 Angular Gripper 163225 Phillips Pan Head Screw 4 BR196012 Gripper Finger 163231 Limit Hex Switch Keps Phillips 314129 Nut 2 Truss Head BR19450 Screw BR196014 Phillips Pan Head Screw 2 BR196080 w Loctite BR199022 Compression Spring BR198012 BR198130 Spacer 163670 Phillips Truss Head Screw BR199426 Explorer Z Axis with IntelliVent Pressure Sensor 541610 Sheet 2 of 4 Information contained in this document is the property of Corporation and may gt Corporation not be copied reproduced or distribu
68. l equipment it may not be possible to determine which diode s is are bad The best course of action maybe to replace all four diodes Make sure the mounting polarity of current transformer T4 is correct See the Assembly Drawing Resistance across R1 measures low due to being paralled by the secondary of current transformer T4 If the resistance across 1 Q then 4 secondary maybe open or unsoldered on the board or at the bobbin pins Resistance across R9 measures low due to being paralled by the primary of current transformer T4 If the resistance across R1 is not very nearly 0 Q then T4 primary maybe open or unsoldered on the board or at the bobbin pins Page 17 of 21 02 10 04 hv test doc rev A High Voltage Board Test Protocol High Voltage will not start or run due to Error Error on Display Possible Problem No Microwaves AC not plugged into high voltage board or 3 pin AC connector header registration is off Low Voltage Select switch set for 230V but unit powered with 120V High Voltage Select switch set for 120V but unit powered with 230V Shorted RTD Defective thermistor on heat sink Short on the circuit board Open RTD Thermistor on heat sink is not plugged in properly Open trace on circuit board Defective thermistor on heat sink Sec Min Range Current transformer T4 bad Check D14 D17 R53 R1 R9 Sec Max Range Page 18 of 21 02 10 04 hv test doc rev A
69. locks and an interlock monitoring system to prevent microwave emission when the attenuator port is not properly installed Two serial ports for computer interface and optional feature connections An ethernet port for network connection optional configuration An infrared Temperature Control System A pressure sensor for feedback control of the system Amagnetic stirrer Acoolinhg system to decrease the temperature of a 20mL solution in 10mL Pyrex reaction vessel from approximately 150 C to 40 C in less than 20 seconds The Explorer Automation Module consists of A Discover Module A software control package for programming and data management An X Y table that delivers 10 mL reaction vessels to the microwave chamber e Four 4 independent Vessel Racks with six 6 positions Adrive motor and table slide in each vessel rack permitting independent movement and loading AZ axis mechanism that integrates a reaction vessel gripper to manipulate vessels An attenuator locking mechanism to seal the reaction vessels in the microwave system Anexternal controller computer optional purchase from CEM Corporation Both systems include application software and an accessory kit Optional features include Fiber Optic Temperature Control System This optional temperature control system for use with large volume open vessel applications uses a fiber optic temperature probe for temperature measurement and c
70. magnetron life temperature control status operation safety interlocks Inboard pressure control system to monitor and control System equilibrium reaction pressure Pressure sensed 200 times per minute Internal pressure control system able to monitor and control vessel pressures up to 300 psi 21 bar Non contact sensor for temperature measurement of vessel contents Temperature sensor independent of vessel volume Temperature measurement range from 15 C to 430 C with an upper control limit of 250 C One panel access to system main circuitry for convenient service and upgrading capability CEM Microwave Systems may be covered by any one of the following U S patents 04835354 04080168 05369034 04672996 RE034373 05230865 04877624 04672996 05206479 05427741 Other patents pending Specifications Electrical Requirements 90 264 VAC 50 60 Hz 1 Amp 120 VAC 0 5 Amp 220 VAC Detachable Power Cord with U L CSA and CE approvals Variance in line voltage can affect microwave power output Instrument Classification Class 1 Continuous Operation Protection Dimensions Explorer Mounted on Discover 20 3 4 D x 14 1 2 W x 30 H 52 7 cm x 36 8 cm x 76 2 cm Weight 40 lbs or 18 1 kg Shipping Wt 46 lbs or 20 9 kg Combined Weight Explorer and Discover 68 Ibs or 30 8 kg Printer Port 25 Pin Epson and IBM Compatible Computer Compatibility 80C188 on board computer controls all system functions System can perf
71. mbly slightly forward Tighten the screw and recheck the belt tension Using steady gentle pressure slide the IR assembly sensor head onto the RF stub Using an Allen wrench tighten the setscrew until snug Do not over tighten the setscrew Connect the cooling gas inlet tubing to the cavity assembly and using a wrench tighten the fitting until snug Install the stirrer cover 162620 by tilting it slightly away from the screw tab engaging the insert tabs and then sliding it in until it stops Install the screw that secures the cover BR128200 and tighten it until it is snug Position the instrument upright on its base Plug the power cord into the electrical outlet Position the on off switch in the on position Stirrer Motor 10 LT 12 13 14 15 16 17 18 19 20 21 22 23 24 29 Position the Discover System power switch in the off position and disconnect the power cord from the electrical source Facing the instrument position it on its left side Remove the stirrer cover 162620 by removing the screw BR128200 that secures the cover then slightly tilting the cover away from the screw tab and lifting it outward to disengage the insert tabs securing the cover Using a wrench disconnect the fitting on the cooling gas inlet tubing and remove the tubing from the cavity assembly Using an Allen wrench loosen the setscrew securing the IR assembly sensor head 541035 to
72. mbly w Removable Needle 541123 Sheet 1 of 2 Information contained in this document is the property of Corporation and may Re 2 2 Corporation not be copied reproduced or distributed without the express written consent of CEM Transducer Assembly Groove must align with screw hole Spring BR198873 Pressure Transducer Cap 162637 Pressure Transducer Finger 162646 Caution Needle protruding through bottom of assembly is very sharp Wire Bushing 163780 Screw 2 BR197528 Cover 162644 Phillips Truss Head Screw 4 BR196011 w Loctite Latch Button 162655 5 2 Place 162695 Wiring Loctite 242 Here BR199022 D N Spring Latch BR198809 Bushing 162650 Retainer Screw 2 162695 w Loctite y BR199022 Latch Finger 162660 Discover Direct Pressure Transducer Assembly w Removable Needle 541123 Sheet 2 of 2 BR199022 Information contained in this document is property of CEM Corporation and may Corporation not be copied reproduced or distributed without the express written consent of CEM Wire Braid 162750 Socket Head Capscrew 4 BR197529 Vessel Mount Ring 162405 Small Vessel Mount 162765 Recess Hole Vessel Ring Tab Socket Head Capscrew 2 BR197532 Attenuator Pin
73. mputer keyboard enter 2000 Press ENTER Ele arg Hrg f Install and tighten the screw securing the right side of the Explorer automation module PZ Axis Show Errors Errors g Locate the Home information and click the All button to home the Explorer automation module h Verify alighment as follows 1 With the gripper fingers completely opened locate Atten Grip attenuator grip and click the associated GO button The pressure sensor assembly will lower Close the gripper fingers to ensure that the fingers will clamp the attenuator at the same time The gripper fingers should be completely parallel vertically and horizontally If necessary carefully reposition the Explorer automation module so that the gripper fingers will be aligned 2 Locate Up in Z Axis information and click the associated button to raise the pressure sensor assembly Note If necessary repeat the above steps to verify the automation module alignment i Proceed to step 29 to continue Explorer module assembly Direct Pressure a Using a small screwdriver or small spatula apply minimual force required to close the gripper fingers If necessary adjust the position of the Explorer automation module so that the gripper fingers are centered around the port of the attenuator b Locate Up in the 2 Axis information and click the associated GO button to raise the pressure sensor assembly
74. ndary current in Power Supply too low No AC voltage to Power Supply Thermal switch or Interlock Power Supply lost Earth Ground Power Supply could not start Pressure Dropped too rapidly Temperature Dropped too rapidly No pressure was detected Plugged Needle Defective Transducer Bad Calibration Pressure Exceeded Maximum allowed 300 psi Lost Communication with Fiso Probe error received form Fiso Vessel was not detected in required rack position Vessel was dropped during insertion or removal Vessel was not released Axis did not go to commanded position Bottom Z Axis switch not actuated while at lock position Z Axis not at home when move began Vessel clamp not operating WARNING Disconnect the instrument from the AC power source prior to performing any service procedure Prior to any troubleshooting or service procedures in the high voltage section or area bridge the contacts of the high voltage capacitor using the metal shaft of a well insulated screwdriver to discharge the residual voltage in the capacitor This will prevent exposure to high voltage discharge during troubleshooting or service Before replacing the high voltage plate assembly after any service procedure involving the microwave generating components visually check the magnetron transformers triac and high voltage capacitor to ensure that the electrical connections are secure Any service to or inspection of the Discover System that requires rem
75. ontrol of the vessel contents It is used only with manual operation of the Discover system The fiber optic probe is an invasive measurement technique and thus requires access to the reaction container from the external environment It connects to the instrument through the second serial port at the rear of the instrument When connected the Discover system automatically detects the temperature sensor and defaults to use this sensor for temperature measurement and control Temperature is programmable from 25 250 Standard Attenuator 541125 Open Vessel Attenuator 541130 WARNING This instrument utilizes high voltages and microwave radiation Only technicians trained in repair and maintenance of high voltage and microwave power systems should perform instrument service and repair WARNING Proper precautions must be taken to avoid contact with solvents or solvent vapors Protective gear should be worn as outlined in the user s safety program for hazardous materials and the reagent manufacturer s material safety data sheet Refer to these guidelines for proper handling and disposal of reagents Routine Maintenance and Cleaning Interlocks Weekly examine the cavity edge and attenuator interlocks to verify that they are clean and working properly Cavity Weekly wipe the cavity liner with an alcohol wipe or equivalent Lubrication Proper lubrication for the Explorer module is CEM part number BR199188 Superlube a syn
76. orm all functions with or without connection to external PC RS 232 9 Pin PC compatible Internal Diagnostic Software BITS System Built In Test System Checks monitors line voltage magnetron life temperature control status operation safety interlocks Operating Temperature 50 F 10 C to 85 F 29 4 C Ethernet and Serial Ports 2 RS 232 9 pin IBM PC compatible Fuses 2 AMP Fuse F2A 250V 1 1 4 Type Littlefuse 312002 3AG CEM BR188250 P S Board F4A 250V Service Accessibility One panel access to system main circuitry for convenient service and upgrading capability Patents CEM Microwave Systems may be covered by any one of the following U S patents 04835354 04080168 05369034 04672996 RE034373 05230865 04877624 04672996 05206479 05427741 Other patents pending Discover Debug Screens To access the debug information screens turn the instrument power on while depressing the EDIT key until an audible BEEP is heard Then release the Edit key The unit will enter the debug code entry mode Enter the Access Code and press the ENTER key Access Code 456 CHO XXXX XXXX CH1 XXXX CH5 XXXX CH2 XXXX CH6 XXXX CH3 XXXX CH7 XXXX The above screen is the analog screen Each channel is listed below CHO Resistor ID 1 should read 0 on current board rev 019611 CHI Resistor ID 2 with pressure device connected channel should read as follows 4095 Stan
77. oval of the power supply assembly replacement of components in the interlock mechanism microwave generation system or microwave transmission system should be followed by a microwave leakage measurement to verify that leakage is less than 5 mW cm Cavity Liner Cleaning Replacement The Discover System 15 equipped with a replaceable cavity liner positioned inside the cavity of the instrument It protects the temperature sensor from debris in case of a vessel failure If a vessel failure occurs the cavity liner should be removed and cleaned or replaced if it is damaged WARNING Proper precautions must be taken to avoid contact with solvents or solvent vapors Protective gear should be worn as outlined in the user s safety program for hazardous materials and the reagent manufacturer s material safety data sheet Refer to these guidelines for proper handling and disposal of reagents 1 Carefully remove the cavity liner by grasping it and pulling it up and out of the cavity using caution to prevent spillage through the opening 2 Rinse the liner with an appropriate solvent to remove all debris 3 Inspect the liner for damage If the liner 15 damaged especially the lens area replace the liner 4 Install the liner into the cavity ensuring that the spout 15 positioned into the spill channel Note If the liner 15 not seated properly the attenuator cannot be installed properly 4 Ifthe cavity liner is replaced calibrate t
78. red in the down position Lower the safety shield 11 The door switch should be in the closed up position 12 Plug the line cord into the power entry module on the rear panel of the Discover unit 13 Ensure that the safety shield is down Using the right front AC power switch turn on the AC power If there is a transistor or driver problem on the board being tested the fuses may blow at this time If the setting of the voltage select switch and the actual measured line voltage do not match a low or high volts alarm will be given 14 Check the heat sink temperature It should read the current room temperature Refer to the Debug Display Data list for the location of the heat sink temperature on the Discover display 15 Follow the directions on the display to begin the test When PLAY is pressed the filament drive will be energized A 2 KHz tone may be audible from inside the Discover unit There will be a three 3 second delay from the time the filament 15 energized until the time that the high voltage transformer is energized When the high voltage starts up if the transistor s driver are going to be a problem they and the fuse s will be gone immediately There may be a slight audible sound buzz generated during the time that the high voltage transformer is energized The high voltage test can be stopped in one of the following four ways e Turn off the door switch the fastest method e Press STOP on the Discover keypad ha
79. rite slug is missing in the winding leg Very bad high voltage waveform at startup This waveform appears as the high voltage starts up Note the difference of the negative portion as seen in Figure 3 The negative portion is smooth with no bumps sort of sinusoidal ACTION Turn off the door switch immediately to stop the power supply when this waveform is seen Do not permit the power supply to ramp up to full power Turn off AC power unplug the unit and disassemble the high voltage transformer to check for improper assembly See Ferrite Core Assembly Page 9 of 21 02 10 04 hv test doc rev A High Voltage Board Test Protocol Ferrite Core Assembly Figure 6 Page 10 of 21 02 10 04 hv test doc rev A High Voltage Board Test Protocol Debug Display Data Line 1 RRR 000 VVV FF CCC Line 4 T SSD HH GGKK Line 1 RRR Runaway counter Starts at 200 when high voltage starts Supply stops at RRR 000 since current cannot be kept in control window 000 Always 000 VVV represents line volts 120 120V 216 230V FF Error flag Byte 2 See below for bit values CCC Magnetron A D current level CCC 720 at 300 watts Current high voltage transformer timing table 1 thru A can be 55 Servo control register to adjust timing or out of the table T This is how current is regulated D Ramp done flag D 1 once the ramp to the current power is done HH Heat sink temperature GG Error flag byte 1 See below for bi
80. rmation contained in this document is the property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Corporation Wire Braid 162750 Socket Head Capscrew 6 BR197529 Small Vessel Mount 163330 Vessel Mount Ring 163660 Phillips Flat Head Screw 4 Attenuator 199415 w Loctite 163336 BR199022 Attenutor Assembly Explorer with IntelliVent Pressure System 541605 Corporation Information contained in this document is the property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM sre Orient Pressure Assembly 541650 as shown leaving clearance between screw head and bracket Pressure Clamping Bracket 163835 Printed Circuit Board E 019632 DN S E OF SSEEEE 5 Pin Terminal age kk BR109915 cSNOYIDOFOO E C 90099999 ETE TEE HRESRESR DOOO0000 8 Pin t gu lab Terminal 33929822 BR108908 mnac o0mz5 Pressure Interface Board 541475 Guide Block 163255 Pressure Support 163705 Socket Head Capscrew 4 BR196446 Q Phillips Truss Head Screw BR128200 w Loctite BR199022 Keps Nut 2 BR130261 Black Wire BR199223 Red W
81. rness by disconnecting the wiring at the two Faston plugs 109931 Facing the instrument position it on its left side Disconnect the cooling gas inlet tubing Remove the cooling solenoid cover 162615 by removing the three screws BR128200 that secure the cover The cover can then be removed by pulling it gently away from the base Disconnect the internal cooling tube from the cooling solenoid Slide the cooling solenoid from its compartment in the base Connect the internal cooling gas tube to the new cooling solenoid Connect the two Faston plugs BR109931 on the cooling solenoid assembly to the wiring harness Slide the cooling solenoid back into its compartment using caution to prevent crimping the wiring connector or inlet cooling gas tubing Install the cooling solenoid cover and secure it to the instrument base with three screws Position the instrument upright on its base Install the top cover assembly 660929 and using the four 4 screws secure it to the base Install the top cover lid 162710 by engaging the front insert tabs and sliding the lid forward until it stops Lower the lid to engage the secure tab at the rear center of the lid until it snaps into place Plug the power cord into the electrical outlet Position the on off switch in the on position High Voltage Supply 1 2 10 11 12 13 14 15 16 17 18 19 20 Position the Discover System power switch
82. round glass joint Load the method created in step 3 and press Start to begin the method At the end of the programmed time 60 sec stir the water thoroughly for 10 seconds then quickly measure and record the peak temperature reading This is the final temperature T The microwave power output is calculated as follows Power in Watts 6 97 If the measured power is below 270W repeat the microwave power measurement If the power remains less than 270W the instrument is not producing adequate microwave power at the 300W selection Remove the Teflon spacer from the floor of the cavity Install the 10mL attenuator access port If the instrument is not producing sufficient wattage refer to the Troubleshooting Guide in this manual Instrument Cold Start While depressing the START key position the instrument power switch in the on position Master Password Login Administrator Password cemdiscover Troubleshooting Guide Condition Possible Cause Instrument Inoperative Instrument modules not plugged into electrical outlet Power switches not in on position Proper instrument not selected in system software Blown fuse s Loose connections to power switch es Faulty power switch es Faulty DC power switch No Microwave Power Low Microwave Power Fuse Blows When Attenuator Is Opened Fuse Blows Repeatedly During Operation Instrument attenuator ajar Zero w
83. s second communications time delay e Wait for the automatic 15 second timeout e Turn off the AC power switch least preferred Things to be vigilant about e First watch the oscilloscope and be ready to turn off the door switch in case the waveform is not as shown in Figure 1 Know the waveforms Once the waveform is determined to be good focus attention on the current meter to observe the ramp up in current e The current level will ramp up to approximately midscale at 150 mA If the current continues to increase toward 180 200 mA turn off the door switch There may be a problem in the current measurement path Page 3 of 21 02 10 04 test doc rev A High Voltage Board Test Protocol 16 When the test is completed e Turn off the AC power using the right front AC power switch e Unplug the power cord from the power entry module on the rear panel of the Discover unit Remove the test board Page 4 of 21 02 10 04 test doc rev A High Voltage Board Test Protocol Good Waveform at Startup Tek ERE 25 0ks s 134 Acqs Figure 1 This frame is made using a correctly assembled high voltage transformer Good high voltage waveform at startup This waveform should be immediate as the high voltage starts up The width of the negative flat portion is representative of the minimal waveform timing used at startup The magnetron is drawing current and acting like a zener diode As the power ramps up to 300 watts the width of t
84. should not be removed Remove the two wires which connect the HV supply cooling fan to the CPU board from the HV supply cooling fan Route the wires through the access in the HVsupply cover located at the right rear of the instrument Remove the two wires which connect the magnetron cooling fan to the CPU board from the magnetron cooling fan Route the wires through the access in the magnetron cooling fan cover located at the left rear of the instrument Label each wire for its proper installed position Using a Phillips screwdriver remove the two screws securing the magnetron cooling fan cover located at the left rear of the instrument Remove the cover CAUTION Ensure the instrument power cord is disconnected Failure to disconnect the power cord could lead to extreme electri cal shock Only technicians trained in high voltage component repair should attempt this repair Locate the two HV wires one black one white connecting the HV supply to the magnetron Using a pair of needlenose pliers remove these wires from the magnetron by pulling the wiring connectors from the magnetron wiring tabs Remove the HV ground strap connecting the internal supply to the waveguide This strap is located below the HV supply cover ground strap on the waveguide Note There are three ground straps located on the same tap Remove the HV supply assembly from the instrument base by grasping the front and back of the supply and tilting it toward the back of
85. t values KK Error flag byte 0 See below for bit values Page 11 of 21 02 10 04 hv test doc rev A High Voltage Board Test Protocol Bit Assignments for Error Flag Byte 0 FIL_ON FLAG VOLTS LO FLAG VOLTS HI FLAG COMM TIME FLAG SHORT RTD FLAG OPEN RTD FLAG TEMP RECVR FLAG ISEC RANGE FLAG EQU EQU EQU EQU EQU EQU EQU EQU 0x00 0x01 0x02 0x03 0x04 0x05 0x06 0x07 FIL ON 1 HS TEMP MUST RECOVER Bit Assignments for Error Flag Byte 1 HI CONTROL FLAG LO CONTROL FLAG TEMP STUCK FLAG RUNAWAY FLAG DOOR OPEN FLAG MIN I SEC FLAG THML OVLD FLAG EGND SENSE FLAG EQU EQU EQU EQU EQU EQU EQU EQU 0x00 0x01 0x02 0x03 0x04 0x05 0x06 0x07 Bit Assignments for Error Flag Byte 2 NO UWAVES FLAG START END FLAG VOLTS SW FLAG Page 12 of 21 EQU EQU EQU EQU EQU EQU EQU EQU 0x00 0x01 0x02 0x03 0x04 0x05 0x06 0x07 1 230 VOLTS 02 10 04 hv test doc rev A High Voltage Board Test Protocol High Voltage Areas on the Board 4000 volts Al Up to 850 volts Up to 400 volts Figure 7 Page 13 of 21 02 10 04 hv test doc rev A High Voltage Board Test Protocol Bottom Side Test Points and Measurements Beedeabebeb Qu bd y CITIL D y X eem D alele imp eee E FH J Kuz 019621 A Fluke 87 True RMS meter was used for the following measurements Figure 8
86. tainer Groove Transducer 314286 Transducer Housing Caution Needle is very sharp 192692 YELLOW WHITE GREEN BROWN Transducer Housing ini 162692 Wiring Diagram Needle Screw 162861 EP 4 162676 Note Torque needle screw to 18 in Ibs Explorer Direct Pressure Transducer Assembly w Removable Needle 541124 Sheet 1 of 2 HH Information contained in this document is the property of Corporation and may gt Corporation not be copied reproduced or distributed without the express written consent of CEM Caution Needle protruding through bottom of assembly is very sharp Wire Bushing 163780 Screw 2 BR197528 Cover 162643 Transducer Assembly Wiring Groove must align Screw 2 with screw hole 162695 Loctite 242 BR199022 BR198873 Pressure Transducer Cap 162638 Pressure Transducer Finger 162646 Explorer Direct Pressure Transducer Assembly w Removable Needle 541124 Sheet 2 of 2 z Information contained in this document is the property of CEM Corporation and may Corporation not be copied reproduced or distributed without express written consent of CEM Fitting 163305 Manifold 163300 Fitting 163315 Note Wrap threads of all fittings with Teflon tape BR199005 Fitting 163325 Manifold Fitting 2 Assembly 163310 Air En Flow 119700 Nut 4 iN BR199450
87. ted on solid supports They accommodate ves sels ranging in volume from 5mL to 125mL for reactions performed under atmospheric conditions and 10mL and 80mL sealed vessels for reactions performed at elevated temperatures and pressures Primary uses of the Explorer and or Discover are in the discovery and lead optimization phases of the drug development process Microwave energy 15 applied to the vessel contents reactants catalysts salts solvents and or solid supports to accelerate the chemi cal reaction The microwave absorption properties of some liquid and solid materials due to their polar and ionic characteristics have the capability to significantly enhance chemical reactions relative to traditional energy application heating techniques The micro wave interaction properties with the reactants intermediates catalysts solid supports and salts provide unique opportunities for the synthetic chemist The Discover System consists of Acontinuous microwave power delivery system with operator selectable power output from 0 300 watts 30 watts programmable in 3 watt increments e A self adjusting single mode microwave cavity that is manually accessed via one of two attenuator ports both ports are included A4 line x 20 character vacuum fluorescent display with alphanumeric keypad and on board computer for programming and operational control of the system The memory will store and recall up to 20 methods e 3 safety inter
88. ted without the express written consent of Phillips Phillips Pan Head Pan Head Screw 2 Screw 4 BR196110 w Loctite w Loctite BR199022 BR199022 Pressure Assembly Setscrew 2 BR197151 Coupling 163400 Rail Phillips 163255 Fillister Head Screw 6 BR196080 w Loctite BR199022 Mn Lead En Screw 163185 Tower Support 163160 Gripper Stop Lead Block T Screw 1631750 Phillips Bushing Truss Head 163360 Screw 2 BR196426 Bearing 163170 Fully Phillips Side Up 2 Retainer Side Up Screw 2 BR196452 163280 Phillips Pan Head Screw 2 BR196018 Explorer Z Axis with IntelliVent Pressure Sensor 541610 Sheet 3 of 4 Information contained in this document is the property of CEM Corporation and may WV S257 Corporation not be copied reproduced or distributed without the express written consent of CEM Bracket 163165 Assembly Braided 541460 Sleeving BR198862 Wire Fitting 163356 Ay Mes Socket Head Capscrew 4 BR196447 7 f A A Fo Aa Phillips Pan Head Screw 2 BR196117 w Loctite Wire Phillips BR199022 Magnet Clamp Fillister Head Retainer BR109976 Screw 163275 BR196080 Proximity Pressure Screw S Magnet Cover BR199403 e
89. thetic grease containing Teflon Microwave Leakage Measurement The attenuator and cavity of the Discover are durable and are designed for reliable operation under severe laboratory conditions External radiation checks are performed on the Discover System at several points in the manufacturing process ensuring that leakage from the finished instrument is only a fraction of that allowed by U S law 5 mW c 2 The attenuator is equipped with a safety interlock system to stop the generation of microwave energy when the attenuator is opened or ajar If the interlock system fails a monitoring mechanism will blow the fuse s through which power is supplied to the magnetron rendering the microwave power system inoperable To verify that seals and interlocks are working properly the Discover System should be tested periodically for microwave leakage Use the following procedure to measure microwave leakage 1 Create a standard method using 300 watts of power 2 minutes run time 95 C temperature set point and 1 minute hold time Place a round bottom flask containing 50mL of demonized water into the cavity Attach the attenuator with RF stub to accept a 24 40 ground glass joint Load the created method and press Start to begin the method Use a suitable RF field strength meter microwave detector such as the Holaday Model HI 1500 Slowly move the RF probe around the attenuator perimeter and around the fan grills to check for microwave le
90. tion contained in this document is the property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM High Voltage Assembly 541110 120V 541155 240V 541180 100V 541185 200V Screw 4 BR128200 IR Option Only Screw 2 BR128200 Magnetron 9 1824900 mmm BR199146 BR199146 472 KZ Fan 184900 Route Magnetron Wiring Thru Opening Discover 908005 Sheet 3 of 9 S Information contained in this document is the property of CEM Corporation and may gt Corporation not be copied reproduced or distributed without the express written consent of CEM Ring lug of Wire 69 on Main Harness Capscrew 2 BR197527 Screw 2 BR196005 Screw 2 BR199403 Surge Board 541455 120V 541550 200 240V Standoff BR145367 Washer 2 BR199472 Discover 908005 Sheet 3A of 9 Information contained in this document is the property of CEM Corporation and may Corporation not be copied reproduced or distributed without the express written consent of CEM Screw 6 Braid Screw 8 BR1 162750 BR197530 w Loctite 242 Choke Lid Upper 162245 Choke Plate 162400 Cavity Washer 6 Choke Lid BR198727 162245 Cavity Protector Cavit 162340 162040 co Alignment Hole for
91. y not FETE Corporation be copied reproduced or distributed without the express written consent of CEM E Ring BR198872 Transducer Assembly Needle Seal 4 162670 LET O ring 162160 Retainer Groove Transducer 314286 Transducer Housing Caution Needle is very sharp 192692 YELLOW WHITE GREEN BROWN Transducer Housing ini 162692 Wiring Diagram Needle Screw 162861 EP 4 162676 Note Torque needle screw to 18 in Ibs Explorer Direct Pressure Transducer Assembly w Removable Needle 541122 Sheet 1 of 2 F Information contained in this document is the property of CEM Corporation and may z z Corporation not be copied reproduced or distributed without the express written consent of CEM Caution Needle protruding through bottom of assembly is very sharp Screw 2 BR196011 Cover 162643 Transducer Assembly Wiring Groove must align Screw 2 with screw hole 162695 Loctite 242 BR199022 BR198873 Pressure Transducer Cap 162638 Pressure Transducer Finger 162646 Explorer Direct Pressure Transducer Assembly w Removable Needle 541122 Sheet 2 of 2 Information contained in this document is the property of CEM Corporation and may not FETE Corporation be copied reproduced or distributed without the express written consent of CEM E Ring BR198872 Transducer Assembly Needle Seal 4 162670 LET O ring 162160 Re
92. y of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Pan Head Screw 4 BR128200 Control Board 541312RA Support Bracket 2 163025 Pan Head Screw 4 BR128200 w Loctite BR199022 Cable Tie BR109975 X Motor A Assembly 4 541465 Pan Head Screw 2 BR196005 Note Motor wires route through this channel Interlock Switch 317070 Note Route wiring through here Socket Head Pinion Capscrew 8 kos emng Gear BR199441 163060 Motor Extension 163095 w Loctite Wire Stepper Motor BR199022 119735 119625 X Motor Assembly Explorer Base Assembly 541415 Sheet 5 of 10 Information contained in this document is property of CEM Corporation and may not be copied reproduced or distributed without the express written consent of CEM Corporation Gripper Valve Assembly 541675 Includes Gripper Valve and Fittings Push Board Forward Jack Screw M w Lock Washer 4 gt BR199087 LO Stop 119740 Control Board Socket Head 1 Assembly us G Val Capscrew 2 Mounting Block 541317RA 0 M CORSI OPBOSIM BR196439 163250 Bracket w Loctite 163055 BR199022 9 Phillips 5 4 Ribbon Cable BR128200 E gt 119755 o ie Wire Holder 25
93. ystem setup information If the calibration data is not known calibration is required 1 From the main menu press EDIT 2 Use the arrow keys to toggle and select Temperature 3 Press ENTER Enter Previous Calibration Values 4 Use the arrow keys and select Enter Calibration Press ENTER 5 Press EDIT to highlight the slope calibration data Using the numeric keypad enter the previous slope constant Press ENTER NOTE Ifa new temperature sensor or cavity liner is installed calibration of the temperature sensor is required due to the dif ference between the IR lenses designed into the cavity liner Calibrate Temperature Sensor 6 Place3mL of dimethyl formamide in a 10mL reaction vessel with a stir bar Place a cloth over the vessel to prevent splattering Disconnect the cooling supply line Using Power Time control program the system to irradiate the reaction vessel at 300W for 30 seconds approximately 150 C 7 Use the arrow keys and select Calibrate Device Press ENTER The instrument will prompt to apply a heat source 8 Press ENTER Note The instrument will not apply microwaves 9 Place a thermometer in the vessel and stir the dimethyl formamide 2 3 seconds Measure the temperature of the dimethyl formamide Using the numeric keys enter the actual temperature Press ENTER 10 Press HOME three times to return to the main menu IR Calibrator When using an IR calibrator CEM part number 541165 use t

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