Service Manual
Contents
1. temperature controller Service Manual Immersion Circulators Heat Only Circulators Refrigerated Heated Circulators With Standard Controllers Before performing any service to the unit reset the controller to its default settings Itis our experience that many problems can be resolved by doing so See Sec 4 1 of this manual for instructions Refrigeration service should only be performed by a qualified refrigeration technician The refrigeration system contains no user serviceable parts This manual is intended for use by qualified service personnel only Disconnect power cord before removing cover exposed voltage when cover is removed Hazard from moving parts present when cover is removed Table of Contents Section 1 Identifying your unit Section 2 Specifications 2 1 General Description Heating and Refrigerated Circulators 9006 9106 9506 9606 9706 8006 8106 8206 8306 2 2 General Description Immersion Circulators 7306 2 3 General Specifications all units Section Maintenance 3 1 Heater 3 2 Pump Motor 3 3 Cleaning 3 4 Maintaining Clear Bath Water 3 5 Condenser Air Vents and Reusable Filter Refrigerated Circulators Only 3 6 Calibration Section 4 Controller 4 1 Resetting unit to Factory Defaults all units 4 2 Removing Controller Cover all units 4 3 Removing Controller from Unit 9106 9006 9506 9706 9606 8006 8106 8206 8306 u2. 240 50 2 6L 9106 9006 20 to 150 C 12 9 9 13L 9506 30 to 150 C 13 9 8 28L 9606 25 to 150 C 13 9 8 131 9706 40 to 150 C 14 9 9 8006 8106 8206 8306 Ambient 5 to 150 C 11 9 8 7306 8306 Ambient 5 to 150 C 11 7 5 The following specifications apply to all units LED C or F 0 25 C 1100W 115V 1600W 240V 15 LPM Over Temperature Protection Yes user adjustable Low Liquid Protection Yes Pump Speed 2 speeds 9 or 15 lpm Pump Inlet and Outlet inch rear discharge except immersion circulator 1 Temperature stability may vary depending on bath volume surface area insulation and type of fluid NOTE Performance specifications determined at ambient temperature of 20 C 68 F Environmental Conditions e Indoor Use Only e Over Voltage Category Il e Maximum Altitude 2000 meters e Operating Ambient 5 to 30 C e Relative Humidity 80 for temperatures to 30 C e Pollution Degree 2 e Class 1 Residential Commercial Light Industrial e Class 2 Heavy Industrial Section 3 Maintenance 3 1 Heater The heater should be kept clean If deposits build up on the heater they may be removed by scrubbing with non metallic abrasive pad Do not use steel wool 3 2 Pump Motor The pump bearings are permanently lubricated with high temperature silicone grease and do not require additional lubrication Should the bearings become noisy replacement of the entire pump motor is recomm
3. 28 Liter Refrigerated Refrigeration Assembly 9606 Diagram 1 Wiring Diagram Controller Models 7306 8006 8106 8206 8306 All heat only circulators 7 2 Wiring Diagrams amp Schematics PUMP SPEED LOW CONTROLLER PCB PUMP MOTOR TEMP PROBE IEC FILTER CIRCUIT BREAKER Division of Preston Industries Inc ay GND 2 SCALE HIS DRAWN BY GND ALLTOLERANCES loma oate 11 4 02 UNLESS OTHERWISE SPECIAIED 031 ASSEMBLY WIRE HARNESS 120 240V FRACTIONS 1 32 DEGREES 2 Diagram 2 Wiring Diagram Controller All Refrigerated Units Model 9006 9106 9506 9606 9706 COMTROL BOARD RN BLE ERN HIRI BRM PZ Fa C 2 7 7 NEUTRAL CIRCUIT BREAKER ATOM CABLE COMPRESSOR GoM COMP RELA NOTES CHM PRESSOR BOARD PAST k 525 512 528529538 COP OVERLOAD Polyiclence Division of Preston Industries Inc SCALE APPROVED BY ALL TOLERANCES GATE 3 99 UH LESS OTHERWISE SPECIFIED 3 1131 DIGRAM FOR 9106 9006 CONTROLLER 29 bd r MATERIAL INITIAL RELEASE 24 REVGION 910 6 DWG NO pd SHEET OF 1 Diagr
4. Unless otherwise required the high limit should be set to maximum 6 8 No power unit shuts down unit trips breaker Check line cord and outlet Increase safety set point OTP Ensure that the included line cord is firmly plugged in at both ends Make sure that the power outlet being used provides power that matches the unit requirements The circulator s electrical requirements are located on the serial number tag at the back of the controller PolyScience circulators include a redundant over temperature feature If the safety set point is set too low the heater will be turned off when the bath temperature reaches the safety set point regardless of the other settings on the control Unless there are specific safety concerns the safety set point should be set at maximum Section 7 Technical Drawings 7 1 Refrigeration Assemblies a oms 2 corens 8 Filter Dryer 7 Low Side Line Solenoid Valve if applicable Fan assembly Fig T 6 Liter Refrigerated Refrigeration Assembly 9106 Filter Dryer Low Side Line Solenoid Valve if applicable Fan assembly Fig V 13 Liter amp 13 Liter Low Temp Refrigerated Refrigeration Assembly 9506 amp 9706 2 Oe 8 He Filter Dryer Low Side Line EE Solenoid Valve if applicable Fan assembly Fig W
5. of the bezel including the RJ45 cable Disconnect all wires See Fig G Loosen the Phillips screw that secures Figure H Temperature probe retaining clip temperature probe to retaining clip of temperature probe Retaining clip 74 screw Figure OTP Retaining Clip Remove controller from unit except immersion circulators see Sec 4 2 Remove 4 screws that secure bezel to controller chassis Remove screw and clips that hold OTP thermostat to heater then remove OTP sensor from heater see Fig Remove bezel assembly being careful to pull the temperature probe up and out of the controller see Fig J Installation of a new bezel is the reverse of the previous steps Remove screw and clip Figure J Removing Bezel From Controller 4 5 Replacing the Compressor Control PC Board 9106 9006 only Figure Compressor Control PC Board 1 Remove the controller and deck plate from the refrigeration assembly along see Sec 4 3 2 Slide the case assembly from the refrigeration assembly 3 Note the color and location of the wires that are connected to the Compressor Control PC Board Disconnect the wires and remove the screws that secure the PCB to the refrigeration unit Installation of a new compressor control PCB is the reverse of the previous steps 4 6 Replacing the PWM Control PC Board 9506 9706 9606 only
6. 1 Remove the controller and deck plate from the PWM Control PC Board refrigeration assembly see Sec 4 3 2 Slide the case assembly from the refrigeration assembly 3 Note the color and location of the wires that are connected to the PWM Control Board Disconnect the wires and remove the screws that secure the PCB to the refrigeration unit Installation of a new PWM control PCB is the reverse of the previous steps 25 4 4 7 Replacing Pump Motor all units Figure Disconnecting Pump Motor Wring 1 Remove controller from unit if applicable and remove cover see Sec 4 2 amp 4 3 2 Note the color and location of the wires which are ae 7 connected to the pump motor at PMPH and amara PMPN Disconnect these 2 wires so er l wires on pump 7 ka speed switch 3 Unsolder the wires connected from the motor to i the pump speed switch Note only the top and F m bottom wire on the switch should be removed the center wire should NOT be removed Pump Motor Ground Wire Figure N Removing Pump Motor from Controller 4 Remove the 4 nuts that secure the pump motor j to the chassis 82 of the 4 nuts that hold pump motor to chassis a Gu HE 4 i w 4 JF 5 Position the controller upside down Remove the screw that secures the Impeller to the pump shaft It is not necessary to futh
7. am 3 PUMP RA5S Diagram 4 Pump power schematics Heater power schematics Rae 274R 0603 1 507 3N WH HOT 02 2401516 220 1 1 1 200 2 NEUTRAL HOT 3401546 51 529802625 929802625 929902825 1 WIREPAD 2 1 WIIREPAD NEUTRAL Diagram 5 Compressor control pc board schematic models 9006 amp 9106 HOT LINE VOLTAGE NEUTRAL FROM HEAD COMPRESSOR HOT Q3 Q4015L6 VAL TO 220 ALT V1 1 HS1 529802B25 529802B25 529802B25 SPADE200 NEUTRAL Diagram 6 PWM control pc board schematic models 9506 9606 amp 9706 COMPRESSOR 1 LH dn 0 r 22 TO DO0 ALT V1 a LINE VOLTAGE SHRUB FROM HEAD 529802825 529802825 SPADE200 00 XFR 1 VAL PL10 46 LWSEL MLSS 100 404 POC 158100 02 1 2 PLUS i 8 03 Jo MINUS 1
8. and covered to reduce the possible heating effect from the ambient air and condensation Check tubing size length and look for Achieving responsive cooling with external applications requires that restrictions and pressure drops adequate fluid flow be maintained Tubing smaller than 1 4 MPT ID will cause flow restrictions and will affect the performance of the unit Also consider the distance from the circulator and number of external devices being controlled when troubleshooting performance problems with the circulator Increase the auto refrigeration setting PolyScience circulators include an auto refrigeration setting that allows the user to specify at what temperatures cooling should be active Unless otherwise specifically required the auto refrigeration setting should be set to the highest temperature Check for refrigerant leaks Sudden changes in the cooling capacity of the unit without changes in the application often indicate a loss of refrigerant To distinguish between a refrigerant loss and compressor failure listen for unusual noise from the compressor Run the unit with no load to determine if any cooling is taking place If there is cooling and no unusual noise from the compressor a refrigerant leak is likely 6 6 Circulation pump problems Set pump speed to maximum Lower pump speeds provide lower flow rates This is especially useful if small diameter tubing is being used or if the fluid path 1 fairly long Not
9. e that circulators in general provide relatively low pressures If the user requires the fluid to be moved over a great distance or up steep inclines consider a chiller or secondary pump Check tubing size length and look for Tubing smaller than 1 4 MPT ID will cause flow restrictions and will restrictions and pressure drops affect the performance of the unit Also consider the distance from the circulator and number of external devices being controlled when troubleshooting performance problems with the circulator Use bypass tube when circulating If the circulator is not being used to circulate fluid to another device or within the circulator tank the included bypass tubing should always be attached to the inlet and outlet of the unit Blocking the inlet and outlet with plugs does not allow for optimum circulation within the reservoir 6 7 Can t Adjust Temperature LLO is displayed on the screen Disable local lockout PolyScience circulators feature a control panel lockout option that can be used to prevent accidental or unwanted changes to the controller settings When active the screen will display LLO or Local Lockout It is enabled and disabled in the same manner Press in and hold the set knob for 10 seconds Check high limit The high limit setting allows the user to limit the functional temperature range of the circulator If the desired set point is beyond the limit setting the user will not be able to set that temperature
10. ended This will reduce repair labor costs and retain fluid pumping reliability 3 3 Cleaning Only mild detergents and water or an approved cleaner should be used on the painted and stainless steel surfaces of the Circulator Do not allow cleaning liquids or sprays to enter the Controller vents 3 4 Maintaining Clear Bath Water When water is used as the bath fluid optimal conditions are present for algae growth To prevent algae contamination and minimize the need for draining the reservoir an algaecide should be used Do NOT use chlorine bleach in the reservoir or on any pump parts 3 5 Condenser Air Vents and Reusable Filter Refrigerated Circulators Only To keep the refrigeration system operating at optimum cooling capacity the condenser the front and back air vents and reusable filter should be kept free of dust and dirt They should be checked f on a scheduled basis and cleaned as required The reusable filter is easily accessed from the bottom front of the unit Turn the filter retaining clip 2222 away from the filter cutout and remove the filter as shown in figure Use a mild detergent and water solution to wash off any accumulated dust and dirt and then rinse and dry thoroughly before reinstalling Figure Removing Air Filter 3 6 Calibration Calibration allows the user to match the Controllers bath temperature display to an external reference thermometer Calibration is pe
11. er disassemble the pump housing 6 Note position of red rubber slinger located where motor shaft meets the bottom of the controller chassis Remove the pump motor from the controller chassis Install the new pump motor by following the previous steps in reverse 4 8 Replacing Pump Impeller all units Figure P Pump Assembly 1 Remove controller from unit if applicable and remove cover see Sec 4 2 amp 4 3 2 Position the controller upside down Remove the screw that secures the impeller to the pump shaft 4 Remove all screws that secure the impeller cover assembly to the heater standoff and OTP sensor see Fig P 5 Remove impeller bottom cover and plate 6 Before removing the impeller note the direction the impeller blades are facing Remove the impeller Install the new upper impeller by following the previous steps in reverse 4 9 Replacing Heater all units 1 Remove controller from unit if applicable and remove cover see Sec 4 2 amp 4 3 2 Disconnect the two brown wires from the heater terminals see Fig Q 3 Loosen the Phillips screw that secures the heater to retaining clip oh Heater retaining clip screw H 4 Position the controller upside down Figure 5 Loosening Heater Retaining Clip Remove the screw that holds the OTP sensor to the pump heater assembly then move the OTM sensor away from the heater For immersion circulators only Fo
12. erature the temperature display of the unit can be offset by using the calibration offset function Make sure the lid is used and that the The included lid should always be used Insulation should be used on fluid path is insulated the entire fluid path wherever possible If an external tank is being used it must be insulated and covered to achieve maximum stability Stability specifications are based on the circulator s internal reservoir External stability may be higher due to heat loss or gain as the fluid travels away from the circulator Check fluid properties PolyScience specifications are based on tests performed with water or water glycol at 20 C ambient room temperatures Fluid properties such as viscosity density specific gravity etc can greatly effect the performance of the unit Use bypass tube when circulating within the circulator Check tubing size length and look for restrictions and pressure drops Increase Auto Refrigeration setting Set pump speed to maximum If the circulator is not being used to circulate fluid to another device or tank the included bypass tubing should always be attached to the inlet and outlet of the unit Blocking the inlet and outlet with plugs does not allow for optimum circulation within the reservoir and can affect stability Achieving good stability with external applications requires that adequate fluid flow be maintained Tubing smaller than 1 4 MPT ID will cause flow restrict
13. ions and will affect the performance of the unit Also consider the distance from the circulator and number of external devices being controlled when troubleshooting performance problems with the circulator Refrigerated units will achieve maximum stability when the refrigeration system is allowed to run even at high temperatures If possible the auto refrigeration setting should be set to the highest possible value Set pump speed to maximum Greater circulation can improve Stability especially when circulating to external devices or tanks 6 2 Accuracy problems displayed temperature varies from that of an external thermometer or device Use calibration offset function 6 3 Heating too slowly Check fluid properties Make sure the lid is used and that the fluid path is insulated Check tubing size length and look for restrictions and pressure drops 6 4 No Heating Increase safety set point OTP Accuracy is the ability of the unit to display temperature within given tolerances to a NIST traceable thermometer The unit includes a calibration offset function which can be used to adjust the displayed temperature to match the users own temperature measurement equipment PolyScience specifications are based on tests performed with water or water glycol at 20 C ambient room temperatures Fluid properties such as viscosity density specific gravity etc can greatly effect the performance of the unit The included
14. lid should always be used Insulation should be used on the entire fluid path wherever possible If an external tank is being used it must be insulated and covered to reduce the possible cooling effect from the ambient air Achieving responsive heating with external applications requires that adequate fluid flow be maintained Tubing smaller than 1 4 MPT ID will cause flow restrictions and will affect the performance of the unit Also consider the distance from the circulator and number of external devices being controlled when troubleshooting performance problems with the circulator PolyScience circulators include a redundant over temperature feature If the safety set point is set too low the heater will be turned off when the bath temperature reaches the safety set point regardless of the other settings on the control Unless there are specific safety concerns the safety set point should be set at maximum 6 5 Cooling too slowly or not enough Check fluid properties PolyScience specifications are based on tests performed with water or water glycol at 20 C ambient room temperatures Fluid properties such as viscosity density specific gravity etc can greatly effect the performance of the unit Make sure the lid is used and that the The included lid should always be used Insulation should be used on fluid path is insulated the entire fluid path wherever possible If an external tank is being used it must be insulated
15. low temp refrigerated circulator gt Controller refers to the upper portion of the unit that includes the PC boards pump and heater In the case of Immersion Circulators the entire unit is the controller Section 2 Specifications 2 1 General Description Heating and Refrigerated Circulators 9006 9106 9506 9606 9706 8006 9106 8206 8306 Refrigerated and Heat Only Circulating Baths with the Standard controller are designed for use as stand alone baths or to provide precise temperature control of fluids for closed loop circulation to external equipment Refrigeration is normally required for operation at temperatures below 30 C All Circulating Bath models feature a reservoir which may be used for immersing samples while the unit is connected to an external device Circulating Bath models are equipped with a 6 13 or 28 liter reservoir All wetted parts are corrosion resistant 300 series stainless steel 2 2 General Description Immersion Circulators 7306 Immersion Circulators with Standard Controllers are designed for use in user supplied reservoirs These units can be used with many sizes and shapes of reservoirs making them extremely versatile and useful for a wide variety of applications They may be used for closed loop applications Operation of the Controller is the same as that for Circulating Bath models 2 3 General Specifications all units Model Type Temperature Amps Amps Range 120v 60Hz
16. n Press and hold the P2 Button while turning the power back ON To reset the unit to default settings and operate in F Place the Circuit Breaker Power Switch in the OFF position Press and hold the Button while turning the power back ON Note When defaulting the unit the high limit value and all temperature presets revert to the factory default values If a calibration value has been entered the value will be retained 4 2 Removing Controller Cover all units Figure Removing Controller Cover Remove the 2 screws that secure the cover to the controller chassis Slide the cover backward and then lift up to remove 4 3 Removing Controller from Unit 9006 9106 9506 9606 9706 Only Figure Removing Controller From Unit Remove the 4 knurled nuts that secure the controller to the lower assembly For refrigerated models disconnect the wiring that is routed to the lower refrigeration assembly Lift the controller up and away from the deck plate Note To remove the controller and top deck plate at once remove the 4 Phillips screws located on the outside edge of the deck plate instead of the 4 knurled nuts that hold the controller to the deck plate 4 4 Replacing Front Bezel Assembly PC Board all units Figure G Disconnecting wirin 1 Remove controller cover see Sec 4 2 2 Disconnect all Note the color and location of the wires which are connected to the terminals on the back
17. nits only 4 4 Replacing Front Bezel Assembly Main PC Board all units 4 5 Replacing Compressor Control PC Board 9006 9106 units only 4 6 Replacing PWM Control PC Board 9506 9606 9706 refrigerated units 4 7 Replacing Pump Motor all units 4 8 Replacing Pump Impeller 4 9 Replacing Heater all units Section 5 Refrigerant Charge for 9006 1006 9506 9606 9706 units only Section 6 Basic Troubleshooting 6 1 Unit Not Pumping all units 6 2 Unit Not Heating all units 6 3 Unit Heats Constantly all units 6 4 Unit Does Not Cool 9106 9006 units 6 5 Unit Does Not Cool 9506 9706 9606 units 6 6 Compressor Runs Constantly 9006 9106 9506 9606 9706 units Section 7 Technical Drawings 8 1 Refrigeration Assemblies 8 2 Wiring Diagrams amp Schematics Section 1 Identifying Your Unit Within this manual units are identified using the following format gt Immersion circulator refers to the immersion circulator with standard controller model 7306 xx Liter Heating Circulator i e 13 liter heating circulator refers to heat only circulators with internal reservoir models 8006 8106 8206 8306 gt xx Liter Refrigerated Circulator i e 28 liter refrigerated circulator refers to heating refrigerating circulators with internal reservoir models 9006 9106 9506 9606 9706 gt Model 9706 13 liter low temperature models will be identified as 13 liter
18. r immersion f circulators Remove these two screws is Remove the screws holding the bracket to bracket the pump assembly 4 7 Remove OTP 5 Remove heater from unit by sliding it down N k TN lt i gt _ out of the controller 2 14 4 S Install the new heater by following the previous steps in reverse Section 5 Refrigerant Charge 9106 9006 9506 9706 9606 only Please note Units are factory charged by refrigerant weight not pressure There are no published refrigerant pressure specifications available as they will vary with fluid temperature 022 Models Refrigerant Type Charge Grams Charge Ounces 9506 R 134a 343 g 12 0102 9706 404 350 9 12 25 oz 9606 R 134a 343 g 12 01 02 Section 6 Basic Troubleshooting 6 1 Stability problems unit will not hold temperature within specified tolerances Confirm problem is with stability not Stability is the ability of the unit to hold a constant temperature within accuracy a specified tolerance Stability is often confused with accuracy which is the ability of the unit to display temperature within a given tolerance based on a known method of measurement If temperature is being held at a constant temperature with little fluctuation but the displayed temperature differs from that of a thermometer or separate device also reading temp
19. rformed as follows Set the desired operating fluid temperature set point and allow temperature to stabilize Press the P2 and P3 simultaneously and release and repeat until the display reads oCx x Press P1 and hold until Cal is displayed This will take about 2 seconds At one second intervals the displayed value will alternate between the actual bath fluid temperature and the current offset value which is the difference between the factory calibration setting and the user s reference temperature sensor maximum offset is 0 9 C from factory calibration To change the calibration offset value rotate the Select Set Knob until the display matches the reading on the reference temperature sensor The display will continue to alternate between the offset value and the calibrated display temperature Press the Select Set Knob or the P1 Button to accept the entered value When the new calibration is stored and the mode is exited AONE will appear on the display NOTE The displayed offset value will also be accepted if there no activity for 20 seconds Section 4 Controller 4 1 Resetting unit to Factory Defaults all units Before performing any service to the unit reset the controller to factory defaults It is our experience that a number of common problems can be resolved by doing so To reset the unit to default settings and operate in C Set Circuit Breaker Power Switch on the rear of the Controller in the OFF positio
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