Cole-Parmer Instrument Company Manufactured by: Barnant Company SERVICE MANUAL MODELS: 77410-10 Masterflex Analog Brushless I/P Drive, 33 to 650 r/min 77411-00 Masterflex Analog Brushless I/P Drive, 33 to 650 r/min, w/ Remote

PROPRIETARY Information contained in this manual is proprietary to the BARNANT COMPANY, division of COLE-PARMER INSTRUMENT COMPANY, INC. No reproduction for other than the intended use of maintaining the product described herein is permitted without the permission of BARNANT. BARNANT COMPANY Division of Cole-Parmer Instrument Company, Inc. 625 East Bunker Court Vernon Hills, Illinois 60061-1844 (847) 549-7600 (847) 247-2929 (Fax) 800-323-4340

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U.S.A. 60010-2392

Cole-Parmer Instrument Company Manufactured by: Barnant Company

TABLE OF CONTENTS INTRODUCTION............................................................................................................. 3 SAFETY CONSIDERATIONS ........................................................................................ 4 FUNCTIONAL DESCRIPTION ....................................................................................... 5 TROUBLESHOOTING .................................................................................................... 7 REPAIR PROCEDURES.............................................................................................. 11 REPLACEMENT PARTS LISTING................................................................................ 13 CALIBRATION .............................................................................................................. 14 FUNCTIONAL TESTS................................................................................................... 15 ASSOCIATED DOCUMENTS ....................................................................................... 17

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U.S.A. 60010-2392

Cole-Parmer Instrument Company Manufactured by: Barnant Company INTRODUCTION Service for this product is performed at three levels: the customer, distributor/COLE-PARMER and factory/depot repair. This manual describes distributor / COLE-PARMER service procedures. Customer service procedures are described in the operator's manual. Customers are encouraged to perform service as described in the operator's 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. Distributor/COLE-PARMER 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. Please refer to the operator's manual for: A) Applications Data B) Product Description C) Installation D) Setup E) Operation F) User Calibration G) User Troubleshooting & Maintenance H) Accessories I) Specifications Page 3

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U.S.A. 60010-2392

Cole-Parmer Instrument Company Manufactured by: Barnant Company SAFETY CONSIDERATIONS Servicing must be performed only by personnel trained and skilled in the methods of troubleshooting and repair of electromechanical products. Use of procedures other than those described in this manual may result in a safety hazard to service personnel and/or customers. When servicing any component of this unit, make absolutely sure that all power to circuitry is removed. Allow ten minutes for the capacitors in the power supply to discharge before proceeding. If any functional checks are to be performed while power is applied and chassis is disassembled, care must be exercised for the following: A) THIS IS A LINE OPERATED DEVICE AND IS NOT ISOLATED FROM GROUND. USE OF AN ISOLATION TRANSFORMER IS HIGHLY RECOMMENDED. B) DO NOT INADVERTENTLY SHORT ANY PART OF THE PRINTED CIRCUIT CARD TO GROUND, AS SEVERE DAMAGE WILL RESULT.

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U.S.A. 60010-2392

Cole-Parmer Instrument Company Manufactured by: Barnant Company FUNCTIONAL DESCRIPTION The Masterflex BLDC I/P® pump drive accurately controls speed, and therefore flow, of attached Masterflex I/P pump heads with load, line voltage and temperature variations over the range of speed settings. A digital signal processor (DSP) in the drive controls both the motor speed and direction, thus allowing direction control to be performed without the use of a large power switch by first bringing the motor to a controlled stop. The high-performance and reliable control of motor speed is accomplished through field-oriented vector control of a state-space modulated, electronically-commutated, three phase brushless permanent-magnet motor. Long-term continuous operation at higher speeds can be achieved, since there are no brushes to wear out and replace. The drive speed is set by a three-turn potentiometer located on the front of the motor/controller enclosure. Set speed is indicated with a digital display with 1% of full scale resolution. The drive has three modes of operation: operator keypad control, remote control by an external 4-20 mA current supply, or remote control by an external 0-10 V voltage supply. External inputs and outputs are provided on the drive to easily interface to larger systems for data logging and for closed-loop process control by means of a PLC. Internal/External operation is selected via a front panel keypad switch. External 4-20 mA and 0-10V inputs are provided on a fluid-resistant circular connector that is located on the rear of the unit. The connector also includes a 4-20 mA output for indicating pump speed and switch closure inputs for External CCW/CW and External Start/Stop. A hand-held control and a footswitch are available to provide optional Start/Stop and CW/CCW operation. The drive assembly is rectangular in shape with controls mounted on the front (plate) of the enclosure, rated IP55. Inside, it has four main parts: a three phase, eight pole, 1/3 HP, BLDC motor, a Masterflex® I/P® gear box, a controller board, and a power line filter. The controller board consists of the power driver, DSP controlled logic, and signal conditioning. The power driver contains an input rectifier bridge, DC link capacitor, and a six IGBT full bridge PWM inverter providing the motor with electronic commutation and voltage and current control. Power semiconductor components are packaged in a power module bolted between the “C” shaped extruded heat sink and the controller board. The controller board also contains all the logic and hardware necessary for the keypad, speed control potentiometer, and external I/O.

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U.S.A. 60010-2392

Cole-Parmer Instrument Company Manufactured by: Barnant Company The front of the enclosure supports a membrane keypad and a three-turn potentiometer used to control speed. A booted on/off power switch, fuse holder, and power cord exit are found on the back of the drive. An IEC 322 power cord accepts domestic and international line cords supplied with the drive.

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U.S.A. 60010-2392

Cole-Parmer Instrument Company Manufactured by: Barnant Company TROUBLESHOOTING Repairs on this unit are confined to the replacement of the unit’s Drive Assembly, Keypad / Display, and Motor Assembly. Where possible, swap known good parts to localize and isolate the problem. VERIFY THAT THERE IS AC POWER. The following is a list of possible problems and remedies: MOTOR DOES NOT ROTATE, DISPLAY DOES NOT LIGHT: 1. 2. 3. 4. 5.

fuse blown unit connected to dead outlet power cord defective AC power switch failure power supply failure

- replace fuse - verify supply is ON - check & replace - replace switch (B-1084-0109) - replace Drive Assembly

UNIT BLOWS FUSES: 1. motor winding / drive failure 2. defective main PCB 3. wrong fuse installed

- check using known good Motor Assembly - replace Drive Assembly - check fuse rating

MOTOR DOES NOT ROTATE, DISPLAY LIGHTS: 1. wrong operating MODE 2. 3. 4. 5.

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defective Remote Control defective keypad defective main PCB defective motor assembly

- MODE set to INTERNAL for front panel operation, mA or V for remote operation - replace Remote Control - replace Keypad / Display - replace Drive Assembly - replace Motor Assembly

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U.S.A. 60010-2392

Cole-Parmer Instrument Company Manufactured by: Barnant Company NO REMOTE OPERATION: 1. defective Remote Control 2. broken lead 3. defective main PCB

- replace Remote Control - check for continuity - replace Drive Assembly

NO DISPLAY OR GARBLED DISPLAY: 1. display connector not seated 2. display failure 3. defective main PCB

- reseat cable (J6) - replace Keypad / Display - replace Drive Assembly

IMPROPER KEYPAD OPERATION: 1. keypad connector not seated 2. keypad failure 3. defective main PCB

- reseat cable (J10) - replace Keypad / Display - replace Drive Assembly

DISPLAYED ERROR CODES Err 1 Err 2 Err 3 Err 4 Err 5 Err 6 Err 7 Err 8

= Invalid Hall effect sensors commutation = Motor overspeed = Over current = Bad flash checksum for program memory, can't run = Over I^2 accumulation = Not used = Bad user setup in EEPROM, using default operator parameter values = Bad EEPROM factory cal data for analog inputs & outputs, using default A/D calibration values Err 9 = EEPROM write/verify error Err 10 = Over bus voltage, can't run Err 11 = Under bus voltage Err 12 = Motor stall Err 13 = PWM module over temperature Err 14 = Ambient over temperature Err 15 = Exceeded open loop current limit Err 16 = Phantom Interrupt, can't run Err 17 = Bad checksum for motor current factory cal data, can't run Err 18 = Motor wires incorrect (only checked in encoder cal mode), can't run Page 8

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U.S.A. 60010-2392

Cole-Parmer Instrument Company Manufactured by: Barnant Company Err 19 = Speed pot wiring error or defective pot / circuitry. INVALID COMMUTATION, ERROR #1 OR #18 DISPLAYED 1. defective motor assembly 2. defective main PCB

- replace Motor Assembly - replace Drive Assembly

MOTOR OVER SPEED, ERROR #2 DISPLAYED: 1. motor overshoot (no tubing in pump) 2. motor overshoot (tubing in pump) 3. defective main PCB 4. defective motor assembly

- press any key to clear error - check for proper tube loading and pump operation, press any key to clear error - replace Drive Assembly - replace Motor Assembly

MOTOR OVERLOAD, ERROR #3, #5 OR #12 DISPLAYED: 1. pump jammed

- clear obstruction, press any key to clear error

ERROR #7 DISPLAYED: 1. bad data 2. bad EEPROM

- press any key to clear error, reprogram operator parameters - replace Drive Assembly

ERROR #10 OR #11 DISPLAYED: 1. line voltage out of range

- press any key to clear error, check that AC

2. defective main PCB

- replace Drive Assembly

line voltage is within specified range

OVER TEMPERATURE, ERROR #13 OR #14 DISPLAYED: 1. heat sources or obstructions for cooling - clear obstruction, allow unit to cool, press any key to clear error 2. pump jammed - clear obstruction, allow unit to cool, press any key to clear error 3. defective main PCB - replace Drive Assembly Page 9

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U.S.A. 60010-2392

Cole-Parmer Instrument Company Manufactured by: Barnant Company SPEED CONTROL WIRING ERROR, ERROR #19 DISPLAYED: 1. broken lead 2. defective speed control 3. defective main PCB

- check for continuity - replace Speed Control Potentiometer - replace Drive Assembly

ANY OTHER ERROR DISPLAYED: 1. internal error or failure

- turn unit off then on and/or press any key to reset, if any error numbers reappear then replace Drive Assembly.

SPECIAL KEY PRESSES 1. To display firmware version number, hold STOP/START key at power up until display changes from "888" to version number. 2. To display or change external mode speed source, press and hold INT/EXT key for 5 seconds until the display changes to the present setting of the external speed source. "4.20" = 4-20mA input, "0.10" = 0-10V input, and "Pot" = potentiometer. Continue holding the INT/EXT key until the display changes to the desired setting. 3. To display or change the scaling for external inputs and outputs, press and hold the INT/EXT key for 5 seconds until the external speed source is displayed ("4.20", "0.10", or "Pot"). Release the INT/EXT key and press the DIR key within 3 seconds. The display will flash "Lo" and then the current speed setting for the low setpoint (4mA or 0V). To change the setting, adjust the speed pot. Press DIR key a second time, the display will flash "Hi" and then the hi setpoint (20mA or 10V). Use the speed pot to change setting and then DIR key to save new settings and return to normal operation. 4. To display/change motor power up option, hold DIR key at power up until display changes to "on" or "oFF" (5 seconds). Keep holding DIR key to change the displayed option. When DIR key is released, the displayed option will be the one used. FOR ADDITIONAL INFORMATION REGARDING YOUR UNIT PLEASE REFER TO THE OPERATOR'S MANUAL. Page 10

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U.S.A. 60010-2392

Cole-Parmer Instrument Company Manufactured by: Barnant Company REPAIR PROCEDURES TO DISASSEMBLE UNIT, PROCEED AS FOLLOWS: A) Disconnect AC power. Allow ten minutes for the capacitors in the power supply to discharge before proceeding. B) Remove the six screws holding the Front Plate Assembly. C) Slide out the Front Plate Assembly. TO REASSEMBLE UNIT, PROCEED AS FOLLOWS: A) Slide in the Front Plate Assembly. B) Install the six screws holding the Front Plate Assembly.

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Cole-Parmer Instrument Company Manufactured by: Barnant Company TO REPLACE DRIVE ASSEMBLY (8817-0001-CR & 8817-0002-CR): A) B) C) D)

Remove the two screws holding the Drive Assembly to the Front Plate Assembly. Remove all cables and wires from the PCB. Replace the two screws holding the Drive Assembly to the Front Plate Assembly. Attach the wiring of Drive Assembly PCB as follows: 1) RED of power line inductor to: J14 2) BROWN of power line to: J15 3) BLACK of motor to: J9 4) RED of motor to: J7 5) WHITE of motor to: J8 6) Cable from motor encoder to: J5 7) Ribbon cables from Keypad / Display to: J6 & J10 8) Cable from front panel Speed Control Potentiometer to: J9 9) Rear Panel Connector ribbon cable to: J12 (77411-00 Only)

TO REPLACE MOTOR ASSEMBLY (E-2125-0001): A) B) C) D) E)

Detach the motor leads. Remove the four bolts holding the motor to the Front Plate Assembly. Remove fan from motor shaft and place on replacement motor. Replace motor and tighten bolts. Attach the motor leads as follows: 1) BLACK of motor to: J9 2) RED of motor to: J7 3) WHITE of motor to: J8 4) Cable from motor encoder to: J5 5) GREEN / YELLOW of motor to Front Plate Assembly ground stud.

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U.S.A. 60010-2392

Cole-Parmer Instrument Company Manufactured by: Barnant Company REPLACEMENT PARTS LISTING The following is a list of stocked main control PCB assemblies, firmware, keypads, motor/drive assemblies, and commonly used parts: DESCRIPTION

BARNANT part #

Fuse – T6.3A Mounting Foot (4 Supplied)

8271-CR

Detachable power cord 115 Vac (USA)

C/P# 50001-68

Detachable power cord 230 Vac (EUROPEAN)

C/P# 50001-70

Line Cord Assembly (Fixed) Power Switch Power Switch Boot

8386-CR B-1084-0109-CR 8072-CR

Drive Assembly (77410-10)

8817-0002-CR

Drive Assembly (77411-00)

8817-0001-CR

Keypad / Display (77410-10)

8858-CR

Keypad / Display (77411-00)

8857-CR

Speed Control Potentiometer

8992-CR

Speed Control Knob

8987-CR

Motor Assembly

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C/P # 77500-24

E-2125-0001-CR

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Cole-Parmer Instrument Company Manufactured by: Barnant Company CALIBRATION Due to the design of this product, there are no calibrations and/or adjustments to be performed other than set-ups performed by the customer. Calibration of the Analog I/O requires a special calibration fixture at the factory. Additional technical specifications are available in the unit's OPERATORS MANUAL.

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U.S.A. 60010-2392

Cole-Parmer Instrument Company Manufactured by: Barnant Company FUNCTIONAL TESTS 1.00

Test equipment required: 1.01 1.02 1.03

2.00

TESTING: 2.01 2.02 2.03 2.04 2.05

2.06

2.07

2.08

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Contact Tachometer (C-P Cat. # 8203-50 or 8203-80) Variac 115 VAC, 60Hz or 230 VAC, 50Hz. Remote Control (C-P Cat. # 7592-83)

Plug controller into the variac set to 115 volts ac or 230 volts. Turn the main power switch to the ON position. Verify that all LED’s, display segments, and decimal points illuminate. Verifying each LED illuminates for CW and CCW, set the drive to the CW direction with the motor DIRection key. 77411-00 only: Press and release the INT/EXT key to display either “lnt” or “EHt”. Press and release the INT/EXT key while this indication is on the display to toggle the mode, if necessary, to the “Int” mode. 77411-00 only: To display or change external mode speed source, press and hold INT/EXT key for 5 seconds until the display changes to the present setting of the external speed source. "4.20" = 4-20mA input, "0.10" = 0-10V input, and "Pot" = potentiometer. Continue holding the INT/EXT key until the display changes to the desired setting. 77411-00 only: To display or change the scaling for external inputs and outputs, press and hold the INT/EXT key for 5 seconds until the external speed source is displayed ("4.20", "0.10", or "Pot"). Release the INT/EXT key and press the DIR key within 3 seconds. The display will flash "Lo" and then the current speed setting for the low setpoint (4mA or 0V). To change the setting, adjust the speed pot. Press DIR key a second time, the display will flash "Hi" and then the hi setpoint (20mA or 10V). Use the speed pot to change setting and then DIR key to save new settings and return to normal operation. To display/change motor power up option, hold DIR key at power up until display changes to "on" or "oFF" (5 seconds). Keep holding DIR key to change the displayed option. When DIR key is released, the displayed option will be the one used. Rotate the speed knob fully counterclockwise and verify display reads “0”. A-1299-1036 Edition 02

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Cole-Parmer Instrument Company Manufactured by: Barnant Company 2.09 2.10 2.11 2.12 2.13

2.14

2.15

2.16

Rotate the speed knob until “5” is displayed, then press STOP/START key on drive. Verify that motor runs smoothly and is rotating clockwise when viewed from the front. The far right decimal point on drive display will be on whenever motor is running. Using the hand tach, verify motor runs at 30.9 to 34.2 RPM. Rotate the speed knob fully clockwise. Using the hand tach, verify motor runs at 648 to 652 RPM and the display reads “100”. 77411-00 only: Press and hold INT/EXT key until the display changes to "Pot" (potentiometer). Press and release the INT/EXT key to display either “lnt” or “EHt”. Press and release the INT/EXT key while this indication is on the display to toggle the mode, if necessary, to the “EHt” mode. 2.14.1 Press the Remote Start/Stop. Verify that there is no effect on the drive. 2.14.2 Press the Remote Prime switch. Verify that the drive runs as long as it is held. 2.14.3 Press the Remote Fwd/Rev switch while holding the Remote Prime switch. Verify that the drive runs CCW as long as it is held. 77411-00 only: Press and release the INT/EXT key to display “EHt”. Press and release the INT/EXT key while this indication is on the display to toggle the mode to the “Int” mode. 2.15.1 Press the Remote Start/Stop. Verify that the drive runs as long as it is held. 2.15.2 Press the Remote Prime switch. Verify that there is no effect on the drive. 2.15.3 Press the Remote Fwd/Rev switch. Verify that there is no effect on the drive. Turn the controller OFF and unplug it from the variac.

************************** TESTS COMPLETED ***********************

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Cole-Parmer Instrument Company Manufactured by: Barnant Company ASSOCIATED DOCUMENTS Current copies of the following documents are required for servicing the drive: Operator’s Manual: Final Assy Dwg Cabinet Assy Dwg: Front Plate Assy Dwg

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U.S.A. 60010-2392