****SERVICE MANUAL****

Transcription

1 ****SERVICE MANUAL**** Pump with fixed speed 1/3 H.P. direct drive motor Pump head only, mounted to pedestal Pump head only, mounted to belt-drive base Pump with variable speed 1/2 H.P. motor, belt driven Pump with variable speed 1/2 H.P. washdown 115VAC motor Pump with variable speed 1/2 H.P. washdown 230VAC motor Pump with adapter for NEMA 56C motor Pump with adapter for IEC F130 motor P R O P R I E T A R Y Information contained in this manual is proprietary to Cole-Parmer Instrument Company,Inc. No reproduction for other than the intended use of maintaining the product described herein is permitted without the written permission of Cole-Parmer. Cole-Parmer Instrument Company, Inc North Oak Park Avenue Niles, IL (708) A Edition

2 TABLE OF CONTENTS SECTION TITLE PAGE 1. INTRODUCTION SAFETY CONSIDERATIONS FUNCTIONAL DESCRIPTION TROUBLESHOOTING REPAIR PROCEDURES REPLACEMENT PARTS LIST CALIBRATION PROCEDURE CHECK-OUT PROCEDURE INTRODUCTION Service for this product is performed at three levels: the customer, dealer and factory/depot repair. This manual describes dealer service procedures. Customer service procedures are described in the Operator Manual. Customers should be encouraged to perform service as described in the Operator Manual as well as in special circumstances where special skills and safety are not considerations. To use this manual begin with the troubleshooting section to isolate the fault to a replaceable part. The Functional Description and Check-out Procedure Sections are also helpful in determining the faulty part. Dealer repair is limited to replacement of modules as detailed in the REPLACEMENT PARTS LIST section. The REPAIR PROCEDURES SECTION details disassembly and assembly procedures. After repair, the product should be calibrated and checked for proper performance. 2

3 Please refer to the appropriate Operator Manual for: APPLICATION DATA PRODUCT DESCRIPTION INSTALLATION SETUP OPERATION USER CALIBRATION USER TROUBLESHOOTING & MAINTENANCE ACCESSORIES SPECIFICATIONS Operator Manual A Operator Manual A SAFETY CONSIDERATIONS DANGER/WARNINGS WARNING: DO NOT OPERATE THIS PUMP UNLESS ALL PROTECTIVE COVERS ARE PROPERLY INSTALLED. ROTATING PARTS CAN CAUSE SERIOUS INJURY. DANGER: HIGH VOLTAGES EXIST AND ARE ACCESSIBLE. UNPLUG UNIT FROM VOLTAGE SOURCE PRIOR TO ATTEMPTING ANY REPAIR PROCEDURE. Servicing must be performed only by personnel trained and skilled in the methods of troubleshooting and repair of electro-mechanical products. Use of procedures other than those described in this manual may result in a safety hazard to service personnel and/or customers. 3

4 3. FUNCTIONAL DESCRIPTION 4

5 Figure wiring diagram Figure wiring diagram 5

6 Figure and wiring diagram 6

7 Figure 4. Pump head assembly (all model numbers) Figure assembly 7

8 Figure assembly 8

9 Figure and assemblies Figure and Brush Replacement 9

10 Figure and Motor Replacement 4. TROUBLESHOOTING The TROUBLESHOOTING section is broken down into two sections. Section 1 addresses only the Rapidload pump head which is common to all models. Section 2 addresses specific model numbers. SECTION 1: PUMP HEAD, COMMON WARNING: DO NOT OPERATE THIS PUMP UNLESS ALL PROTECTIVE COVERS ARE PROPERLY INSTALLED. ROTATING PARTS CAN CAUSE SERIOUS INJURY. PROBLEM POSSIBLE SOLUTION Occlusion knob spins on its 1. Retighten set screw. shaft. (Fig. 4.)(Sect ) Occlusion knob will not turn. 2. Clean retracting screw and regrease with Magnalube. (Fig. 4.)(Sect ) Roller will not turn. 3. Replace roller assembly. (Fig. 4.)(Sect ) Protective cover is cracked. 4. Replace protective cover. (Fig. 4.) SECTION 2: SPECIFIC MODELS 10

11 WARNING: DO NOT OPERATE THIS PUMP UNLESS ALL PROTECTIVE COVERS ARE PROPERLY INSTALLED. ROTATING PARTS CAN CAUSE SERIOUS INJURY. DANGER: HIGH VOLTAGES EXIST AND ARE ACCESSIBLE. UNPLUG UNIT FROM VOLTAGE SOURCE PRIOR TO ATTEMPTING ANY REPAIR PROCEDURE (Figures 1 and 5) PROBLEM POSSIBLE SOLUTIONS Motor does not power up when 1. Reset circuit breaker. turned on. (Fig. 5.) Motor powers up, but rotor 2. Gearsarestripped, replace does not turn. motor.(fig. 5)(Sect ) (Figures 2 and 6) PROBLEM POSSIBLE SOLUTIONS Motor does not power up when 1. Check wire connections. turned on. (Fig. 2.) 2. Replace controller fuse. (Fig. 6.) 3. Replace motor brushes. (Fig. 6)(Sect 5.3.1) Motor powers up, but rotor 1. Replace drive shaft/bearingdoes not turn. assy.(fig.6.)(sect ) 2. Replace V-belt.(Sect ) and (Figures 3 and 7) PROBLEM POSSIBLE SOLUTIONS Motor does not power up when 1. Check wire connections. turned on. (Fig. 3.) 2. Replace controller fuse. 11

12 (Fig. 7.)(Sect ) 3. Replace motor brushes. (Fig. 7.)(Sect ) 4. Replace motor. (Fig. 7.)(Sect ) Motor powers up, but rotor 1. Adjust "max." and "min" speed does not turn. pots if seals are broken. (Fig. 7.)(Sect. 7.0) 2. Replace gear reducer. (Fig. 7.)(Sect ) 5. REPAIR PROCEDURES 5.1 PUMP ONLY(Figure 4) Roller Assembly: Remove roller assembly from rotor by removing retaining ring on end of shaft. Remove assembly from shaft. Replace assembly. Press down on roller and replace retaining ring Rotor Assembly: Remove rotor assembly from drive shaft by loosening the set screw in hub with an 1/8" allen wrench and sliding rotor assembly forward. Place new rotor assembly onto drive shaft and slide assembly back until it is / in. from main bracket. Use a feeler gage to ensure proper distance from bracket. Make sure that key is in proper location, tighten set screw onto key to in-lb Occlusion Handle: Remove occlusion knob by loosening set screwsin base of knob using a 3/32" allen wrench. Slip new knob onto shaft and tighten set screws onto flat on shaft to in-lb Retracting Screw/Nut: Remove pointer from occlusion ring. Loosen both button head screws that hold the occlusion nut to main bracket by using a 5/32" allen wrench. Remove screw/nut assembly by sliding assembly forward out of the "T" slot. To reassemble, follow directions in reverse. Tighten screws to in-lb. 12

13 (Figures 1 and 5) Motor: Remove plastic cover from front of pump head. Remove rotor assembly from drive shaft by loosening the set screw in hub with an 1/8" allen wrench and sliding rotor assembly forward. Place unit on edge of bench with pump head pointing upwards. Remove four flat head screws that attach motor to main bracket by using a 5/32" allen wrench. Slip main bracket off motor. Replace motor, tighten mounting screws to in-lb. To reassemble, follow directions in reverse and tighten rotor hub set screw to in-lb (Figures 2 and 6) Motor Brushes: Remove brush covers on both sides of the rear of the motor. Remove brushes and replace Drive Shaft/Bearing Assembly: Remove rotor assembly from drive shaft by loosening the set screw in hub with an 1/8" allen wrench and sliding rotor assembly forward and set aside. Remove rear pulley cover. Loosen set screw on pulley hub with a 5/32" allen wrench and slide pulley off shaft. Loosen set screw on collar of shaft/bearing assembly using a 3/16" allen wrench and remove collar. Remove defective assembly by pushing it out towards the rear of the pump head. Insert new shaft/bearing assembly into split collar from rear of pump head by pressing on the outer race of the bearing. Pressing on either end of the shaft could damage the bearings.replace collar onto split collar and tighten set screw to in-lb. Reassemble pulley and rotor to shaft. Tighten pulley set screw to 9-11 ft-lbs V-Belt: Remove and discard old V-belt. Place one end of belt over small pulley on motor shaft. Run opposite end of belt onto large pulley by feeding a small amount at a time onto pulley while simultaneously turning the pulley and -35(Figures 3 and 7) Controller Fuse: To access controller fuse use a No. 2 phillips head screw driver to remove the four screws that hold the cover to the body of the controller. Carefully push cover to the side as 13

14 there will still be wires connected to it. Make sure all the wires are connected properly. If fuse is blown replace fuse with appropriate fuse.(see sections 6.4 and 6.5). Replace cover and retighten cover screws to in-lbs Motor Brushes: WARNING: Power must be removed from motor before performing this procedure. Cut off power to the motor by disconnecting line cord. Do not assume that turning off the switch at the motor (or controller) is "safe enough." To access the motor brushes, remove the six screws securing the access plate and remove plate (see Figure 8). Loosen screw terminal at top of brush housing and disconnect brush wire. Press down on brush retainer to disengage the tabs then rotate brush retainer slightly toward front of motor and remove brush retainer. Slide assembly out of housing. Install new brush assembly brush wire to the rear of the motor and sprin assembly top. Insert brush retainer against brush springs and down, then rotate retainer slightly toward rear of motor to engage tabs of retainer under rear edge of brush housing. Attach brush wire to screw terminal at top of brush housing. Be sure wire is clear of access opening. Attach cover plate with six screws. Tighten screws to in-lbs. Note: Always replace both brushes at the same time Motor: WARNING: This product is intended for use with a motor that 1725 RPM. Do not use a motor with a higher speed capacity. has a maximum speed of WARNING: Electrical connections and grounding(earthing) must conform to local wiring codes. Using a 5/16 inch hex key, remove the four bolts that attach the motor to the adapter (see Figure 9). Using a 9/16 inch remove the four bolts that attach the motor feet to the base. Carefully, slide motor away from pump head. Using a 1/8 inch hex key, loosen the set screw that 14

15 attaches the shaft coupling to the motor shaft. Place coupling on new motor shaft and make sure the that it is fully engaged until it stops on the shaft. Retighten set screw to in-lbs. Place motor onto mounting feet. NOTE: The pump rotor may need to be rotated for alignment in the next step. Slide motor forward to engage the male motor coupling with the female gear head coupling. Rotate pump rotor if necessary to align the couplings. Using a 5/16 inch hex key, bolt the motor to the gear head adapter by inserting the four bolts through the gear head adapter into the motor. Torque bolts to ft-lbs. Using a 9/16 inch wrench, secure the motor to the mounting bolts to 9-11 ft-lbs. feet using the four bolts. Torque Gear Reducer: Remove motor from gear reducer adapter per Sect To replace gear reducer remove bolts that attach the gear reducer adapter to the gear reducer using a 5/16 inch hex key. Using a 1/8 inch hex key loosen set screw on rotor assembly hub and remove rotor. Using an adjustable wrench remove the four spacers and remove the gear reducer from the pump. Replace gear reducer and tighten spacers to ft- lbs. Replace gear reducer adapter and tighten four mounting screws to ft-lbs. Replace motor per Sect REPLACEMENT PARTS LIST 6.1 PARTS COMMON TO ALL PUMP HEADS DESCRIPTION PART NUMBER QTY PER UNIT Handle (occlusion adjust) A-4215-CR 1 Knob (tubing retainer) B

16 Pointer A-4355-CR 1 Protective Cover D-2618-CR 1 Roller Assembly B-3329-CR 3 Magnalube A-4356-CR as required DESCRIPTION PART NUMBER QTY PER UNIT Gearmotor E Motor spacers B Motor screws B Motor lock washers B Rubber Feet (w/screws) A-4216-CR and DESCRIPTION PART NUMBER QTY PER UNIT 90 Vdc motor ( only) E Fuse, 10 Amp ( only) B Vac controller ( only) D V-Belt A Small pulley (w/set screw) B Large pulley (w/set screw) B Drive shaft/bearing assembly B Drive shaft collar (w/set screw) B

17 DESCRIPTION PART NUMBER QTY PER UNIT 90 Vdc washdown motor E Brush A-4156-CR 2 Fuse, 10 Amp B Shaft adapter (w/set screw) A Gear reducer D Washdown controller D Rubber feet (w/screws) A-4216-CR DESCRIPTION PART NUMBER QTY PER UNIT 180 Vdc washdown motor E Brush A-4158-CR 2 Fuse, 5 Amp B Shaft adapter (w/set screw) A Gear reducer D VAC washdown controller D Rubber feet (w/screws) A-4216-CR DESCRIPTION PART NUMBER QTY PER UNIT Shaft adapter (w/set screw) A Gear reducer D

18 Rubber feet (w/screws) A-4216-CR DESCRIPTION PART NUMBER QTY PER UNIT Shaft adapter (w/set screw) A Gear reducer D Rubber feet (w/screws) A-4216-CR CALIBRATION PROCEDURE (Models and -35 only) DANGER: HIGH VOLTAGES EXIST AND ARE ACCESSIBLE. UNPLUG UNIT FROM VOLTAGE SOURCE PRIOR TO ATTEMPTING ANY REPAIR PROCEDURE. Models and have trimpots inside their controllers. To access trimpots remove 4 screws on controller cover with a standard phillips screw driver. These pots are sealed in the proper positions. The optimum settings for these pots are: Note: 12:00 on all trimpots is indicated by a fiducial mark Trimpot "o'clock setting" MIN 11:00 MAX 10:00 ACCEL 11:00 IR COMP 10:00 CUR LIM 8: Trimpot "o'clock setting" MIN 11:00 MAX 10:00 ACCEL 11:00 IR COMP 10:00 CUR LIM 8: CHECK-OUT PROCEDURE 18

19 No load conditions, pump without any tubing loaded: Controller set to zero, rotor speed = 0 RPM Min. rotor speed less than or equal to 12 RPM Max. rotor speed 350 to 360 RPM Nominal load conditions, pump loaded with -90 Norprene at nominal occlusion: Controller set to zero, rotor speed = 0 RPM Min. rotor speed less than or equal to 12 RPM Max. rotor speed 350 to 360 RPM 8.1 As a final check load pump with size -90 Silicone. Pump should produce a minimum of 8 gallons per minute flow rate at nominal occlusion, 72 degrees F, 350 RPM, and 0 psi backpressure and 0 in. of water lift. 19