5800 Power Supply Replacement Instructions

5800 Sampler
Power Supply Module
Instruction Sheet 60-4702-059
Revision D, January 20, 2016
Removal and Replacement Instructions
Overview
This power supply module is a component of the
Teledyne Isco 4700 and 5800 refrigerated samplers.
These instructions cover removal and replacement of
the module in both 115 VAC and 230 VAC models. When
necessary, the steps will specify the model to which the
instructions apply.
Before attempting to remove and replace a module,
observe the following precautions:
WARNING
Removing a module exposes you to electrical and
mechanical hazards. Always disconnect the AC
power cord before attempting to remove any
module. Only trained service personnel may
remove or replace these modules.
Removing the Module - Serial Number
216B and Newer
Complete the following to remove the existing
refrigerator module.
1. Unplug the line cord to remove the AC power.
2. Remove the coil shield, back cover, and
insulation panel (Figure 1). When removing the
foam insulation panel, take precautions not to
damage the foam around the tubing (see inset,
Figure 1).
Refrigeration module
Foam insulation panel
Back cover
CAUTION
Modules contain circuit boards and sensitive electronics
that can be damaged by a discharge of static electricity.
Avoid touching the internal components. Only handle
the module by the edges or exterior surfaces.
Coil Shield
CAUTION
Electrical connectors and wires can be damaged if
improperly handled. Electrical connectors must only be
handled by the connector body. Never grasp the wires
or use tools to disconnect a connector. Never allow a
module to hang by its wiring.
Foam insulation panel
CAUTION
Earth ground bonding conductor. Do not
remove or disconnect. If this conductor must
be disconnected to remove a module, it must
be reconnected when installing the
replacement module.
Required Parts and Tools
●
●
●
●
1
Replacement power supply module:
❍
115 VAC sampler (P/N 60-5804-190) or
❍
230 VAC sampler (P/N 60-5804-194)
❍
Clear silicone sealant (Serial Number 216B
and Older only)
❍
Nylon cable tie (P/N 489-0110-00)
❍
#2 and #3 Phillips screwdrivers
Figure 1: Open rear compartment
3. Cut the cable tie holding the power cord that
runs through the refrigeration assembly
(Figure 2).
Cut cable tie
15
/16" open-end wrench
11
/32" nut driver or socket wrench
Wire cutters
Figure 2: Cut cable tie to free line cord
Instruction Sheet 60-4702-059 Revision D, January 20, 2016
4. Remove the refrigeration module mounting
screws (Figure 3).
5. Carefully pull the module out and rotate
clockwise to expose the wiring connectors. The
bushing holding the AC line cord in place should
slide along the cord (see inset, Figure 3). During
reinstallation, the slack created in this step must
be removed.
b. Slide the bushing sideways away from the
refrigeration module until it is free (Figure 5).
Avoid bending the refrigeration tubing.
c. Pull the power cord through the refrigeration
module.
Bushing
CAUTION
Keep the module as close to the refrigerator body as
possible to avoid pulling the wiring taut and damaging
the connectors.
Pull module out and
rotate clockwise
Figure 5: Remove power cord
7. For 115V wire connections, remove the terminal
cover of the compressor (Figure 6). For 230V
wire connections, skip to step 10.
Line cord bushing
Figure 3: Remove refrigeration module mounting
screws
6. Remove the power cord and complete the
following steps.
a. 230 VAC Models Only – Remove the AC Plug
adapter from the end of the power cord by
first cutting away the plastic heat shrink
tubing. Pull the adapter off, leaving just the
North American 115 VAC plug (Figure 4).
Figure 6: Access compressor overload and relay8.A
screwdriver may be used to release the latch.
Figure 4: Remove adapter from power cord
(230 VAC models Only)
9. Disconnect the four (4) compressor wires from
the power supply cable (Figure 7).
a. While holding the overload relay in place,
disconnect the brown wire.
b. Disconnect the blue wire from the capacitor
and relay assembly from the gray wire on the
power supply cable.
c. Disconnect the black heater wire from the
black wire on the power supply cable.
Instruction Sheet 60-4702-059 Revision D, January 20, 2016
d. With the 11/32" nut driver or socket wrench,
remove the nut holding the green/yellow
ground wire on the module chassis.
Gray
Blue
Brown
b. Disconnect the blue wire from the capacitor
and relay assembly from the gray wire on the
power supply cable.
c. Disconnect the black heater wire from the
black wire on the power supply cable.
d. With the 11/32" nut driver or socket wrench,
remove the nut holding the green/yellow
ground wire on the module chassis.
Black
Brown
Heater
Wire
Blue
Green/
yellow
Figure 7: Electrical connections on 115V
compressor
10. For 230V wiring, remove the terminal cover off
the compressor (Figure 8).
Black
Gray
Heater
Wire
Green/
yellow
Figure 9: Electrical connections on 230V
compressor
12. Open the top cover of the sampler and remove
the control panel mounting screws (see
Figure 10).
Figure 8: Access compressor overload A screwdriver
may be used to release the latch.
11. Disconnect the four (4) compressor wires from
the power supply cable (Figure 9).
a. Disconnect the brown wire from the
compressor terminal.
Note
Note the terminal location for the re-installation
process. Do not hook the brown wire to the same
terminal that the green wire connects to.
Figure 10: Remove control panel
13. Lift the control panel away from the refrigerator
body to expose the wiring connectors.
14. Disconnect the wiring connectors.
a. 5800: Connectors P1 and P10
b. 4700: Connectors P11 and P14
15. Place the control panel back on the refrigerator
body and start at least two screws to
Instruction Sheet 60-4702-059 Revision D, January 20, 2016
temporarily hold the panel until the new harness
is in place.
16. With a 15/16” wrench, unscrew the black
cord-grip fitting from the bulkhead fitting in the
rear wall above the upper right corner of the fan.
With #2 Phillips, remove the nylon cable clip.
Pull the control panel power cable out through
the threaded opening.
Note
Turn the connector sideways to fit through the hole.
Power supply
cables
Adhesive strips
Figure 13: Power supply back plate
Bulkhead
fitting
Cord grip fitting
Replacement
1. Mount the replacement power supply with the
two Phillips screws.
CAUTION
Cable
clip
Figure 11: Cord grip fitting on refrigerator rear wall
17. From the front interior of the refrigerator,
remove the two Phillips screws holding the fan
in place and disconnect the fan’s power cable
(Figure 12).
Cable
connector
Earth ground bonding conductor. Ensure
that the green/yellow wire is reconnected to
this terminal.
2. Route the line cord through the refrigeration
module and secure it in place with the bushing.
Hold the line cord taut to remove any slack, and
attach a cable tie 489-0110-00 (Figure 35).
CAUTION
When installing/replacing the refrigeration unit, the line
cord MUST be properly secured. This is to ensure that
the cord cannot be pushed into the enclosure and be
caught in the fan.
Cable Tie
Bushing
Figure 12: Remove fan mounting screws and disconnect cable (view from inside refrigerator)
18. Inserting the #3 screwdriver through the holes in
the heater plate, remove the two Phillips screws
from the power supply back plate and remove
the power supply (Figure 13).
Figure 14: Secure AC Power Cord (Full length of line
cord not depicted)
a. 230V/50 Hz Systems Only — Attach the 230V
plug adapter to the end of the power cord.
Slide the piece of plastic heat shrink tubing
over the plugs. Then apply heat of at least
80°C (176°F) to shrink the tubing.
Instruction Sheet 60-4702-059 Revision D, January 20, 2016
d. With the 11/32" wrench, connect the green/
yellow ground wire with the nut to the
threaded standoff on the frame.
3. Reinstall the terminal cover on the compressor.
CAUTION
Figure 15: 230V line cord plug adaptor
3. Reconnect the cable connectors of the
replacement power supply to the fan, and
reinstall the fan with its two mounting screws.
4. Route the CPU CBA connector cable up through
the refrigerator and into the top compartment.
Connect the harnesses to the back of the control
panel.
a. 5800: Connectors P1 and P10
b. 4700: Connectors P11 and P14
5. Hand tighten the cord-grip. Use pipe sealing tape
on the threads.
Earth ground bonding conductor. Ensure that
the green/yellow wire is reconnected to this
terminal.
4. Slide the refrigeration module to the rear of the
refrigerator and place the drain tube in the drip
pan on the module (Figure 17).
Module Replacement
Complete the following to reinstall the refrigerator
module:
1. Ensure that the control wiring runs through the
channel in the refrigerator body (Figure 16).
Figure 17: Position drain tube in front half of the drip
pan
Note
Two thick, black cables connect the power supply with
the AC and compressor (Figure 16). Ensure that
cables are side by side and not crossed during
reassembly.
5. Ensure the black gasket is aligned and gasket
nubs are inserted in corresponding holes on the
frame of the refrigerator module (Figure 18).
Gasket
Nub
Power supply
cables
Adhesive strips
Note
Figure 16: Rear view with module removed
2. Reconnect the four (4) compressor wires to the
power supply cable (Figure 9):
a. Connect the brown wire to the compressor
terminal.
b. Connect the gray wire from the power supply
to the blue wire from the capacitor and relay
assembly.
c. Connect the black wire from the power
supply to a black wire from the heater.
Figure 18: Position gasket on refrigeration module
frame and ensure each gasket nub is inserted in
corresponding hole
6. Route the AC power cord through the
refrigeration module and secure it in place with
the bushing (Figure 19).
Instruction Sheet 60-4702-059 Revision D, January 20, 2016
9. Install the cable tie to secure the power cord
that runs through the refrigeration assembly
(Figure 21).
Bushing
CAUTION
During reinstallation, ensure the slack in the power cord
is removed before fastening the cable tie.
Figure 19: Secure AC Power Cord (Full length of line
cord not depicted)
Install
cable tie
CAUTION
When reinstalling the refrigeration module, do not pinch
the sensor wiring.
7. Install the module, tipping the top back while
sliding the bottom forward. When the bottom of
the system is in place, push the top into place
(Figure 20). Ensure the slack in the power cord is
removed before securing refrigeration module
frame.
Push top
in second.
Figure 21: Install cable tie to secure power cord
10. Reinstall the coil shield, back cover, and
insulation panel (Figure 1). When installing the
foam insulation panel, take precautions not to
damage the foam around the tubing (see inset,
Figure 1).
11. Attach the adapter to the AC power cord’s North
American connector. Place the adhesive heat
shrink tubing equally over the connection. Apply
heat using a heat gun until the shrink tubing
evenly conforms to the connector and adapter.
Figure 22: 230V line cord plug adapter
Push
bottom in
first.
Figure 20: Slide module into place
CAUTION
When reinstalling all self-tapping screws, avoid
destroying the plastic threads. First seat each screw in
its hole and, without pressing down, rotate the screw
counter-clockwise until it falls into its thread groove with
a “click.” Then tighten the screw.
8. Reinstall the refrigeration module mounting
screws (Step 4).
12. Restore AC power to the 5800 refrigerator.
13. Review the refrigerator temperature diagnostic
test, as described in the following section.
14. Reinstall the refrigeration module mounting
screws (8), insulation panel/back cover screws
(5), and cover brace screws (2).
Instruction Sheet 60-4702-059 Revision D, January 20, 2016
Removing the Module - Serial Number
216B and Older
Complete the following to remove the existing
refrigerator module.
1. Unplug the line cord to remove the AC power.
2. Remove the cover brace, back cover, and
insulation panel (Figure 23).
Refrigeration module
CAUTION
Keep the module as close to the refrigerator body as
possible to avoid pulling the wiring taut and damaging
the connectors.
Pull module out and
rotate clockwise
Insulation panel
Back cover
Cover brace
Adhesive strip
Line cord bushing
Figure 23: Open rear compartment
3. Cut the cable tie holding the power cord that
runs through the refrigeration assembly
(Figure 24).
Figure 25: Remove refrigeration module
6. Remove the power cord.
a. 230 VAC Models Only – Remove the AC Plug
adapter from the end of the power cord by
first cutting away the plastic heat shrink
tubing. Then pull the adapter off, leaving just
the North American 115 VAC plug (Figure 26).
Figure 24: Cut cable tie to free line cord
4. Remove the refrigeration module mounting
screws (Figure 25).
Note
Note that the refrigeration module has an adhesive
strip just above the rear coils. The bottom center
screw may be slightly hidden by this.
5. Carefully pull the module out and rotate
clockwise to expose the wiring connectors. The
bushing holding the AC line cord in place should
slide along the cord (see Figure 25, inset). During
reinstallation, the slack created in this step must
be removed.
Figure 26: Remove adapter from power cord
(230 VAC models Only)
b. Slide the bushing sideways away from the
refrigeration module until it is free
(Figure 27). Avoid bending the refrigeration
tubing.
Instruction Sheet 60-4702-059 Revision D, January 20, 2016
Bushing
Figure 27: Remove power cord
c. Pull the power cord through the refrigeration
module.
7. Remove the terminal cover of the compressor
(Figure 28).
Figure 29: Electrical connections on 115V compressor
Figure 28: Access compressor overload and relay
A screwdriver may be used to release the latch.
Note
The following connections are from the power supply
on the rear of the cabinet and will vary according to
the type of capacitor. If the power supply was replaced
after 216B (February of 2016) refer to 216B and newer
wiring instructions
Figure 30: Electrical connection in 230V compressor
8. Open the top cover of the sampler and remove
the control panel mounting screws (see
Figure 31).
Instruction Sheet 60-4702-059 Revision D, January 20, 2016
Cable
connector
Figure 33: Remove fan mounting screws and disconnect cable (view from inside refrigerator)
Figure 31: Remove control panel
9. Lift the control panel away from the refrigerator
body to expose the wiring connectors.
10. Disconnect the wiring connectors.
a. 5800: Connectors P1 and P10
b. 4700: Connectors P11 and P14
11. Place the control panel back on the refrigerator
body and start at least two screws to
temporarily hold the panel until the new harness
is in place.
12. Unscrew the black cord-grip fitting from the
bulkhead fitting in the rear wall above the upper
right corner of the fan. With #2 Phillips, remove
the nylon cable clip. Pull the control panel power
cable out through the threaded opening.
14. Inserting the screwdriver through the holes in
the heater plate, remove the two Phillips screws
from the power supply back plate and remove
the power supply (Figure 34).
Note
Turn the connector sideways to fit through the hole.
Figure 34: Power supply back plate
Bulkhead
fitting
Cord grip fitting
Cable
clip
Replacement
1. Mount the replacement power supply with the
two Phillips screws.
2. Reconnect the wires to the compressor and
replace its cover.
CAUTION
Figure 32: Cord grip fitting on refrigerator rear wall
13. From the front interior of the refrigerator,
remove the two Phillips screws holding the fan
in place and disconnect the fan’s power cable
(Figure 33).
Earth ground bonding conductor. Ensure
that the green/yellow wire is reconnected to
this terminal.
3. Route the line cord through the refrigeration
module and secure it in place with the bushing.
Hold the line cord taut to remove any slack, and
attach a cable tie 489-0110-00 (Figure 35).
Instruction Sheet 60-4702-059 Revision D, January 20, 2016
Closing the Rear Compartment
CAUTION
When installing/replacing the refrigeration unit, the line
cord MUST be properly secured. This is to ensure that
the cord cannot be pushed into the enclosure and be
caught in the fan.
Cable Tie
Bushing
Ensure that the control wiring runs through the
notches in the plastic refrigerator body.
The refrigeration module and rear compartment of
the cabinet have adhesive strips and Permagum1
(caulking cord sealant) protecting the components
(Figures 37 and 38). Ensure that all adhesive strips and
Permagum are still in place before reassembly.
The adhesive strips and Permagum are required to
prevent air flow between the condenser coil and the
evaporator plate. Without this protection, water
condensation on the coil will cause ice build-up,
resulting in poor refrigerator performance.
Note
Two thick, black cables connect the power supply with
the AC and compressor (see Figure 37). Ensure that
these cables are side by side and not crossed
during reassembly.
Figure 35: Secure AC Power Cord (Full length of line
cord not depicted)
a. 230V/50 Hz Systems Only — Attach the 230V
plug adapter to the end of the power cord.
Slide the piece of plastic heat shrink tubing
over the plugs. Then apply heat of at least
80°C (176°F) to shrink the tubing.
Permagum
sealant
Figure 36: 230V line cord plug adaptor
4. Reconnect the cable connectors of the
replacement power supply to the fan, and
reinstall the fan with its two mounting screws.
5. Route the CPU CBA connector cable up through
the refrigerator and into the top compartment.
6. Coat the threads of the black bulkhead
connector with 737 RTV sealant (800-1002-03).
Screw the bulkhead connector into the
refrigerator cabinet by hand until the threads
bottom out. Smooth the RTV out to cover the
joint.
7. Connect the harnesses to the back of the control
panel.
a. 5800: Connectors P1 and P10
b. 4700: Connectors P11 and P14
Power supply cables
Adhesive strips
Figure 37: Rear view with module removed (
Adhesive strips, Permagum sealant, power cables)
1. Permagum is a registered trademark of the Presstite Engineering
Company.
Instruction Sheet 60-4702-059 Revision D, January 20, 2016
Adhesive
strip
Center
screw
Push top
in second.
Permagum
sealant
Figure 38: Rear view of refrigeration module
(Adhesive strip, Permagum sealant)
8. Move the refrigeration module up to the rear of
the refrigerator and replace the drain tube in the
drip pan on the module.
Push
bottom in
first.
Figure 40: Slide refrigeration module into place
CAUTION
When reinstalling all self-tapping screws, avoid
destroying the plastic threads. First seat each screw in
its hole and, without pressing down, rotate the screw
counter-clockwise until it falls into its thread groove with
a "click." Then tighten the screw.
10. Reinstall the refrigeration module mounting
screws (8), insulation panel/back cover screws
(5), and cover brace screws (2).
Figure 39: Position the drain tube in front half of
the drip pan
9. Reinstall the refrigeration module, tipping the
top back while sliding the bottom forward. When
the bottom is in place, push the top into place.
Teledyne Isco
P.O. Box 82531, Lincoln, Nebraska, 68501 USA
Toll-free: (866) 298-6174 • Phone: (402) 464-0231 • Fax: (402) 465-3001
E-mail: IscoService@teledyne.com
Teledyne Isco is continually improving its products and reserves the right to change product
specifications, replacement parts, schematics, and instructions without notice.
Last modified January 20, 2016
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