Troubleshooting CryoSmart 1
Contents
1. IN 27 MEE Rel i IN 29 Co 15V AC mi 390 43 15 agitation IN 31 NC O Lg 80 JjThermstr N 32 51 Thermistor n 3 N 33 m Thermistor Shield 55 Pt100 56 8V AC CPU 60 _ 12 V sensors 61 12 V AC sensors 35 FAN The fan system takes the heat produced by the peltier cell out of the unit PRINTER COMMUNICATION The communication from the board up to the printer is realized with a RS232 communication interface J2 Board PRINTER Male RX1 TX1 TX1 RX1 RX0 RX0 TXO 36 FUSES The instrument has 2 fuses of 6 3 A each To replace the fuses please follow this procedure 1 Disconnect the cryoscope from the main supply 2 Open the fuse compartment 3 Replace the fuses 1 Main switch 2 Fuse compartment 3 Supply connector FEATURES Mechanical features Dimensions 255 x 360 x 370 mm Weight 18 5 Kg Electrical features Power supply 230 V 50 Hz Electrical consumption 150 W Overload fuses 2 x 6 3 A Main supply voltage maximum fluctuations 10 of the nominal voltage Transient overvoltages 11 Board CryoSmart2 Software 1 5 Operating features Maximum altitude 2000 m Maximum relative humidity 80 for temperatures up to 31 C decreasing linearly to 50 relative humidity at 40 C Ope2. 2 Adjust the agitation see Agitation Adjustment 3 Adjust the freezing stroke see Freezing Stroke Adjustment 4 Check the entire fluidic system Check the tubes they must be clean check the pumping system check the liquid inside the tank see Rear Panel check the filter replace it if necessary 5 Check the position of the thermistor see Thermistor Adjustment 6 Check the fixing of the thermistor 7 Check the connections or replace the thermistor THE INSTRUMENT UNDERVALUES THE SAMPLES Problem The result of the analysis is undervalued Causes 1 The sample is too cold 2 The freezing stroke is too weak 3 The thermistor is broken Solutions 1 Check the milk temperature 2 Adjust the freezing stroke see Freezing stroke adjustment 3 Replace the thermistor THE INSTRUMENT OVERVALUES THE SAMPLES Problem The result of the analysis is overvalued Causes 1 The thermistor is broken solutions 1 Replace the thermistor THE FUSES BLOW Problem When you switch the instrument on the fuses blow Causes 1 Diodes bridge failure 2 Power supply failure Solutions 1 Check the diodes bridges 2 Check the power supply system INSUFFICIENT TEMPERATURE OF THE BATH WAIT Problem The instrument does not keep the working temperature Causes 1 Cooling bath failure 2 Cooling bath control system failure Solution 1
3. 513 0 510 _ 00 0 O 4 Switch the instrument off and on if you change the linearity value 20 CHAPTER 4 INSTRUMENT PARTS CryoSmart 1 DOES Mandrel Thermistor and Stirrer Duct Front panel Head Actuator Rear Panel Grate 21 CryoSmart 20 5 Mandrel Actuator Carousel Rear Panel Grate Thermistor and Stirrer Front Panel 22 BLOCK DIAGRAM PELTIER CELL STEP MOTOR ACTUATOR DISPLAY CryoSmart 20 PROGRAM MEMORY PERISTALTIC PUMP CPU STIRRER FLASH MEMORY RS232 POWER PHOTOCELL NTC PT100 MICRO RLITTONS SUPPLY CryoSmart 20 SWITCHES FAN N 3 FRONT PANEL I E ws Ka vx es Display MENU CAL ESC DOWN START STOP OK UP A SIR The keys have two different colours the white side runs the operational functions of the instrument the orange side allows the visualization and modification of the functions after entering the MENU The e button allows to enter and to scroll through the functions It allows to scroll through the calibration menu The START STOP OK key is used to start or stop the analysis Pay attention put the sample first and then press START When the START key is pressed and the analysis has started the display s
4. Check the cooling bath Peltier cell 2 Check the T2 IRF540 MOSFET transistor THE CAROUSEL DOES NOT ROTATE CryoSmart 20 Problem A the carousel does not rotate When you press Causes 1 Rotation system failure 2 The microswitch is not correctly pressed Solutions 1 Check the correct functionality of the rotation system mechanical and electrical 2 Check the correct functionality of the microswitches inside the actuator WITH THE SAMPLING TUBE LOADED THE HEAD DOES NOT GO DOWN Problem The tube is inside the duct but the head does not come down Causes 1 Wrong position of the photocell 2 Photocell failure Solutions 1 Check the position of the photocell see correct position of the photocell 2 Replace the photocell THE HEAD DOES NOT MOVE Problem The head does not move but the photocell is in a correct position Causes 1 Microswitches failure 2 Actuator failure Solutions 1 Check the microswitches 2 Check the actuator THE STIRRER DOES NOT WORK Problem The stirrer does not work Causes 1 Magnet failure Solutions 1 Check the magnet connections THE STIRRER BREAKS THE SAMPLING TUBES Problem The stirrer breaks the sampling tubes Causes 1 The freezing stroke is too strong Solutions 1 Adjust the freezing stroke see freezing stroke adjustment THE INSTRUMENT DOES NOT PRINT ANY DATA Problem The instrume
5. Troubleshooting CryoSmart CryoSmart 20 ASTORI TECNICA di Astori Claudia amp s n c Via Stelle 11 25020 Poncarale BS Italy Phone no 39 030 2540240 Fax no 39 030 2640812 E mail info astorioscar com www astorioscar com Troubleshooting CryoSmart 1 CryoSmart 20 ASTORI SERVICE DEPARTIMENI u i uuu unus ala 4 CHAPTER 1 PROBLEMS AND SOLUTIONS 5 THE INSTRUMENT RETURNS SAMPLE FAILED 5 THE ANSIRUMENI RETURNS TIME OU 5 THE INSTRUMENT DOES NOT RUN THE eect eee m 6 BAD REPEATABILITY OF THE INSTRUMENT 6 THE INSTRUMENT UNDERVALUES THE cece ence eee 7 THE INSTRUMENT OVERVALUES THE SAMPLES 7 THE FUSES BLOW ilaele 7 INSUFFICIENT TEMPERATURE OF THE BATH 8 THE CAROUSEL DOES NOT ROTATE CryoSmart 20 8 WITH THE SAMPLING TUBE LOADED THE HEAD DOES NOT GO DOWN 8 THE AIEAD DOES NOW MOVE glielo 9 TEE STRRER DOES NOT WORK T uD natin oe lous naa dean ela 9 THE STIRRER BREAKS THE SAMPLING sess 9 THE INSTRUMENT DOES NOT PRINT ANY cece ee
6. by pressing a 2 Search for Stirrer Test 3 Press Press E to start the test Unlock the adjustment trimmer see Rear panel Decrease the value by turning it anticlockwise Lock the trimmer again O m 14 8 9 Press FE Run some new tests to check for the undesired possibility to break a tube f the freezing stroke is too weak follow the steps here below QUOD co Enter the main menu by pressing a Search for Stirrer Test Press Press E to start the test Unlock the adjustment trimmer see Rear panel Increase the value by turning it clockwise Lock the trimmer again Press Run some new tests to check for the undesired possibility to break a tube LOCKING SYSTEM TRIMMER 15 CORRECT POSITION OF THE PHOTOCELL CryoSmart 20 The correct position of the photocell is described in the next pictures The photocell must point over the semisphere uut RTN SS SSS SS SSSA SS SS SSS 16 THERMISTOR REPLACEMENT To replace a thermistor please follow the procedure as described here below 1 Disconnect the instrument from the main supply 2 Open the head 3 Unscrew the screw the one with the hexagonal socket in its head that fixes the thermistor at the mandrel see Thermistor Adjustment 4 Get the soldered cables free from their insulation coats see Head o Unsolder the thermistor
7. cables 6 Extract the thermistor from the mandrel by pulling it down 7 Insert the new thermistor from the bottom of the mandrel Please pay attention Do not hit the thermistor glass ball 8 Solder the cables of the new thermistor Check that the new solders are done correctly 9 Insulate the solders 10 Check the thermistor position see Thermistor Adjustment 11 Fix the thermistor 12 Fix the cables of the thermistor be careful not to tend them and not to place them too close to the stirrer and or the magnet see Head 13 Close the head 14 Proceed with a new calibration procedure see Calibration 17 CHAPTER 3 ANALYSIS AND CALIBRATION ANALYSIS The correct analysis of the cryoscopic point should respect the following curve 1 Start analysis 2 Agitation 3 Freezing stroke 4 Plateau 18 CALIBRATION Before running each calibration procedure check the condition of the calibration standards Gently turn the bottle upside down and rotate it several times to mix its content thoroughly The standard solutions should not be used if the bottle is filled for less than one quarter in comparison to its total capacity The shelf life of the standards covers 12 months from the date of production To perform a correct calibration procedure please follow the instructions here below 1 Enter the main menu by pressing the e button 2 Search for Calibration Reset Press the button P
8. control board directly A PID controller pilots the MOSFET transistor IRF540 The fan system gets the heat produced by the Peltier cell out of the equipment see Fan PELTIER To YL IRF540 Board 27 SPRING Inside the cooling bath there is a spring for the sample tube Pay attention The spring must be positioned in the duct exactly as described in the picture below CryoSmart 1 UP CryoSmart 20 The spring must be at the same level of the bath s duct If the spring is positioned higher than the duct probably will be dragged by the tubes If the spring is too low probably will prevent the carousel rotation SMALL UP BIG DIAMETER 28 HEAD Inside the head there are the following components the magnet the lamina who allows the stirrer swing and the connections of the thermistor Lamina Magnet Stirrer support Thermistor cables Head Centering nut Magnet clamper Stirrer cables Mandrel D OT oN To center the stirrer please follow this procedure 1 Unscrew the nuts and move the lamina until the stirrer is in the correct position see Stirrer Adjustment 2 Screw the nuts again One method to adjust the Freezing Stroke and the agitation is by moving the magnet Unscrew the screw the one with the hexagonal socket in its head that clamps the magnet in order to approach and move away the magnet from the stirrer support 1 By mo
9. e eee eee 10 CHAPTER 2 ADJUSTMENT uev eet dpud us quU nd oe 11 THERMISTOROADJUS TEN T aiite leali 11 SHRRERADIUSIMENT aspirata oa 12 AGITATION ADJUSTMENT alli 13 FREEZING STROKE ADJUST MBEBDNT piazza 14 CORRECT POSITION OF THE PHOTOCELL CryoSmart 20 16 THERMISTOR REPLACEMENT usunanpaq un Steal e erat dd D odas msn Uit 17 CHAPTER ANALYSIS AND CALIBRATION eee eee eect eee ee eee m nemen enn ene ena 18 ANALYSIS 18 CALIBRA TON a Rael aero 19 CHAPTER 4 INSTRUMENT ceti aaa 21 Problema 21 BLOCK DIAGRAM ETE 23 E 24 REAR PANE E 25 DATEI Aia die Su apa a sub o 26 SPRING eee 27 arca 29 MANDRE C ER 30 MOTOR C NOS Meant 20 acie aa OA 30 er TTT 31 EER 33 ACTUATOR eee 33 BOARD Tcr 34 RA RE RR E 36 PRINTER COMMUNICATION rca ea 36 LR saka ha 37 FEATURE Sis P 37 ASTORI SERVICE DEPARTMENT In case of any trouble please contact our SERVICE DEPARTMENT at the telephone number 39 030 2540240 fax number 39 030 2640812 or by e mail at service astorioscar com This manual was made to clarify the most frequent troubles and how to solve the proble
10. hows the sample temperature the reference value to calculate the added water percentage and after the freezing stroke has done the added water percentage of the sample The START STOP key is also used to give confirmations OK and it allows to enter and confirm the functions of the menu The CAL ESC key when used as ESC allows to exit the functions of the menu When used as CAL it allows the calibration of the instrument The keys aa are used to manually lower and raise the head by pressing and releasing the proper key 24 REAR PANEL fe e gt Automatic refilling tube Filter Trimmer Data input Program Printer Cooling liquid tank Waste Main switch Fuses compartment 10 Supply connector 11 Peristaltic pump 5 Q N AEE 11 25 BATH The bath is cooled by means of a Peltier cell 15 V AC at 7 0 5 1 Duct 2 Cooling bath body 3 Cooling system The replacement of the liquid inside the bath is possible by the external bottle the peristaltic pump and the waste tube When the instrument is turned on the refilling of the bath is performed automatically At the end of every analysis the cooling liquid is completely replaced thanks to the circuit just described 26 WASTE DUCT BOTTLE The temperature control in the bath is realized like in the figure below The PT100 probe sends data to the electronic
11. lf is properly placed inside the calibration standard To check the agitation strength please follow this procedure Enter the main menu by pressing Search for Agitation Test 3 Press 4 Fill a tube with a calibration standard up to the level volume normally used with a sample during a common analysis 5 Place the tube under the mandrel as a normal analysis should be performed 6 Press E to start the test press E f the agitation looks too strong or too weak follow these steps 1 Enter the main menu by pressing a 2 Search for Agitation Amplitude 3 Increase or decrease the value by pressing E to finish the test CORRECT 13 WRONG FREEZING STROKE ADJUSTMENT The correct freezing stroke must hit the walls of the tube stir all the liquid avoid the breakage of the tubes To adjust the freezing stroke please follow this procedure 1 Enter the main menu by pressing 2 Search for Stirrer Test 3 Press 4 Fill a tube with a calibration standard up to the level volume normally used with a sample during a common analysis 5 Place the tube under the mandrel as a normal analysis should be performed 6 Press eo to start the test press E to finish the test 7 Runa lot of tests to check if the undesired possibility to break a tube exists f during a test the stirrer breaks a tube proceed like described here below 1 Enter the main menu
12. ms occurring to our cryoscopes when our technical assistance is not necessary In this manual you will find lots of possible causes describing problems evaluated by the technical assistance Detailed descriptions are listed problem by problem along with clear explanations about how to solve them However please do not hesitate to call us in case of any problem you might find moreover we would like to remind you that all our cryoscopes include a 12 month warranty period starting from the purchase date Kind regards Astori Tecnica s n c CHAPTER 1 PROBLEMS AND SOLUTIONS THE INSTRUMENT RETURNS SAMPLE FAILED Problem The result of the analysis is SAMPLE FAILED Causes 1 The freezing stroke is not strong enough for milk samples 2 Thermistor failure or not connected Solutions 1 Adjust the freezing stroke see Freezing Stroke Adjustment 2 Check the connections of the thermistor 3 Replace the thermistor If you press g the head goes down and immediately the instrument makes the freezing stroke check the connections of the thermistor and or replace it THE INSTRUMENT RETURNS TIME OUT Problem The result of the analysis is TIME OUT Causes 1 The analyzed sample is too cold 2 he milk is altered high presence of salts urea etc 3 he temperature of the bath is too high or too low 4 The agitation is too strong and air bubbles are created inside the sam
13. nt does not print the results of the analyses or the parameters Causes 1 Communication failure solutions 1 Check the connections of the printer see Printer communication 10 CHAPTER 2 ADJUSTMENTS THERMISTOR ADJUSTMENT The correct position of the thermistor is showed here below The glass ball of the thermistor must be at the center of the semisphere and at 35 5 mm from the mandrel S LL RSI SESSO B mF rr E lt NS CR 1 Mandrel 2 Tube 3 Thermistor 4 Stirrer If the position is not correct please follow this procedure 1 Unscrew the screw with the hexagonal socket in its head that fixes the thermistor at the mandrel 2 Place the thermistor in the correct position 3 Fix the thermistor at the mandrel 4 Check the clamping of the thermistor 11 MANDREL HEX KEY STIRRER ADJUSTMENT The stirrer and the thermistor have to be at the same level see Thermistor adjustment The stirrer must be centered like shown in the picture here below and it must vibrate symmetrically and freely inside the slot see mandrel and see head Mandrel Thermistor Slot Stirrer Q N 12 AGITATION ADJUSTMENT The agitation must avoid the production of air bubbles inside the tube This adjustment procedure can be made by using a calibration standard In perfect working conditions the maximum stirrer amplitude is 2 3 mm when the stirrer itse
14. oves the head up and down The microswitches are located inside the actuator 33 BOARD The board allows all the following operations Move the head Rotate the carousel Read data from the photocell Control the cooling bath Pilot the stirrer Read data from the thermistor Communicate with the printer HMI Human Machine Interface oo I Mm 8 J2 61 CITI IL i E sss Lu 9 C HHI Doo m ae m m _ Wn IRF540 PIN 1 PhotocellA 2 Photocell B 3 jPhotcell 12 OUT _ 5 4 Photocel GND j OUT 6 8 NC 6 Microswiteh Common IN 7 7 1 8 Microswitch Down 9 NC 10 34 12 j StpMotr O 13 StepMotor 14 StepMotor IN 2 15 StepMotor 3 B 16 9 V AC step motor IN 14 17 9 V AC step motor IN 15 22 9 6 23 Actuator CST 17 24 12V AC actuator IN 18 19 _ 9 V lt AC pumo Pm OUT 2 x 33 12V Peltier 24 34 Rel Stirer O OUT 25 35 Rel Stirrer C UT 26 36 IN O 37 NC O 38 NC y o 39 OV transformer stirrer
15. ple the sample is freezed before 3 C 5 The volume of the cooling liquid is not enough 6 The carousel did not rotate CryoSmart 20 7 The magnet is disconnected see Head Solutions 1 Check the temperature of the milk sample Too cold samples freeze before the freezing stroke 2 Verifiy using other methods if the milk sample has been altered Check the temperature of the bath 7 C 0 5 C 4 Adjust the agitation see Agitation adjustment 5 The sample tubes must be clean please check for it The pump must replace the liquid at the end of every analysis and the filter must be clean see Bath Filter and Pump 6 Check the correct rotation of the carousel or the spring position see Spring 7 Check the magnet connections THE INSTRUMENT DOES NOT RUN THE ANALYSIS Problem During an analysis the temperature of the sample is the same one of the bath but no error is displayed Causes 1 The lower microswitch is not correctly pressed Solutions 1 Check the lower microswitch inside the actuator BAD REPEATABILITY OF THE INSTRUMENT Problem The instrument does not show a good repeatability Causes Altered samples Bad adjustment of the agitation Bad adjustment of the freezing stroke Wrong temperature of the bath Wrong position of the thermistor Broken thermistor or bad connections Oo O IS Solutions 1 Check the integrity of the samples
16. rating temperature from 5 C to 40 C Storage temperature from 10 C to 50 C 37
17. ress again to confirm Clean the mandrel the thermistor and stirrer with a piece of soft paper Prepare 1 sample of the 0 408 C calibration standard p gr ms 7 Start the analysis by pressing 8 Wait until the end of the analysis and press the button M f to confirm the calibration 11 Clean the mandrel the thermistor and the stirrer with a piece of soft paper 12 Prepare 1 sample of the 0 600 C calibration standard 13 Start a new analysis by pressing 14 Wait until the end of the analysis then press the button 15 Press 16 Press EE 17 Press again to confirm Now a new calibration procedure is necessary Repeat the operations from step 5 to 17 using 3 replicates for each calibration standard Check the repeatability of the values if the repeatability is bad check the thermistor for any breakage maybe it requires a replacement After finishing the calibration procedure run a new analysis with 5 replicates of the 0 512 C calibration standard 19 If the repeatability of the 5 replicates looks good but the value is different from 0 512 C follow this procedure 1 Enter the main menu by pressing 2 Select To Linearize 3 Increase or decrease the value if the results are overvalued or undervalued using the buttons Any variation of 5 on Linear means 0 001 C Example VALUE READED LINEARITY MODIFY NEW VALUE 0
18. ving the magnet closer the freezing stoke becomes gentler and its working quality improves but the agitation becomes too strong 2 By moving the magnet away the agitation works better but the freezing stroke increases its power and a breakage of the sample tubes becomes possible Find the better position where both agitation and freezing stroke work correctly Then clamp the magnet again After finishing these operations adjust the agitation and the freezing stroke see Agitation Adjustment and Freezing Stroke Adjustment 29 MANDREL The thermistor and the stirrer are located inside the mandrel MOTOR CryoSmart 20 The step motor moves the carousel 30 The pump is the element that allows the refilling of the liquid inside the cooling bath CLIP A CLIP A CLIP B If the pump is dirty an insufficient volume of liquid may be replaced inside the bath To clean and replace the tube please follow this procedure 1 Release the pump by pressing the A clips 31 2 Open the pump by pressing the B clips 3 Replace the tube 32 FILTER If the filter is dirty the cooling liquid cannot fill the cooling bath properly so that the results may be inaccurate Replace the filter when decribed Pay attention Place the filter in the right position The arrow on the filter body must be addressed upfront UP ACTUATOR The actuator is the component that m
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