NORMALAB NDI 450 Operation and maintenance manual

NORMALAB France
2012
N O R M A L A B F r a n c e
1/118
NORMALAB France
MAINTENANCE NOTICE
NDI 450

NORMALAB France
2012
N O R M A L A B F r a n c e
2/118
1CONTENTS
1CONTENTS 2
2STRUCTURE OF THE MACHINE 6
2.1MECHANICAL STRUCTURE 6
2.1.1 HEATING BLOCK 6
2.1.2 SUBSET COMPARTMENT 6
2.1.3 SUBSET CONDENSER 7
2.1.4 THE VENTILATION 7
2.2 ENVIRONNEMENT OF THE MACHINE 8
2.3 ELECTRONIC STRUCTURE 9
2.3.1 ELECTRONIC STRUCTURE 9
2.3.2 LOCATION OF THE ELECTRONIC BOARDS 9
2.3.3 THE EXTERNAL CONNECTIONS 11
3INSTRUCTION SHEETS 12
3.1 ACCESS TO PARTS OF THE MACHINE 12
3.1.1 OPENING THE PANELS 12
3.1.2 REMOVING THE FRONT PANEL 13
3.1.3 ACCESS TO THE ELECTRONIC DRAWER 15
3.2 LEVEL FOLLOWER 16
3.2.1 REPLACEMENT OF THE 1RST DROP OPTICAL SENSOR 16
3.2.2 REPLACEMENT OF THE FOLLOWER OPTICAL SENSOR 17
3.2.3 REPLACEMENT OF THE LIMIT SWITCHES OF FOLLOWER 18
3.2.4 REPLACEMENT OF DRIP DEFLECTOR DETECTOR 19
3.2.5 REPLACEMENT OF STEP BY STEP MOTOR 22
3.2.6 REPLACEMENT OF THE MOTOR BOARD 24
3.2.7 REPLACEMENT OF DETECTOR OR MAGNET OF COMPARTMENT DOOR 25
3.3 HEATING BLOCK 26
3.3.1 REPLACEMENT OF THE HEATING ELEMENT 26
3.3.2 REPLACEMENT OF TURBINE 27
3.3.3 REPLACEMENT OF FIRE DETECTION THERMOCOUPLE 28
3.3.4 REPLACEMENT OF VAPOR PROBE’S DETECTOR 29
3.3.5 REPLACEMENT THE MECHANICAL SYSTEM OF SAMPLE PROBE DETECTION 30
3.3.6 REPLACEMENT OF HEATING BLOCK DOOR’S DETECTOR 30

NORMALAB France
2012
N O R M A L A B F r a n c e
3/118
3.4 CONDENSER 31
3.4.1 REPLACEMENT CONDENSER PROBE 31
3.5 COOLING CONDENSER SYSTEM 32
3.5.1 REPLACEMENT OR DRAIN OF THE COOLANT LIQUID CIRCUIT 32
3.5.2 REPLACEMENT OF PUMP 32
3.5.3 REPLACEMENT OF FILTER OR FAN 35
3.5.4 REPLACEMENT OF FAN 36
3.5.5 REPLACEMENT OF FAN SPEED THERMOSTAT 36
3.5.6 REPLACEMENT OF PELTIER SUBSET 37
3.5.7 ADJUSTMENT OR REPLACEMENT OF THE LIQUID LEVEL DETECTOR 40
3.5.8 REPLACEMENT OF SUBSET PELTIER POWER SUPPLY 41
3.6 COMPARTMENT COOLING SYSTEM 42
3.6.1 REPLACEMENT OF THE FILTERS OR FANS 42
3.6.2 REPLACEMENT OF THE PELTIER SUBSET OF RECEIVER COMPARTMENT 43
3.6.3 REPLACEMENT OF THE COMPARTMENT PROBE 46
3.6.4 REPLACEMENT OF SUBSET PELTIER POWER SUPPLY 47
3.7 CHASSIS 47
3.7.1 REPLACEMENT OF THE HEATING TRANSFORMER 47
3.7.2 REPLACEMENT OF THE HEATING FUSE 48
3.7.3 REPLACEMENT OF THE CIRCUIT BREAKER 49
3.7.4 REPLACEMENT OF THE CL3 BOARD 50
3.7.5 REPLACEMENT OF THE AMBIENT PROBE 51
3.8 ELECTRONIC DRAWER 51
3.8.1 REPLACEMENT OF THE CL1 BOARD 51
3.8.2 THE BAROMETRIC SENSOR 52
3.8.3 REPLACEMENT PROCESS OF THE MICROPROCESSOR BOARD 53
3.8.4 REPLACEMENT OF THE POWER SUPPLY OF UC BOARD OR STEP BY STEP MOTOR 53
3.9 FRONT PANEL 54
3.9.1 REPLACEMENT OF MMI MICROPROCESSOR BOARD 54
3.9.2 REPLACEMENT OF THE HARD DRIVE DISK 54
3.9.3 REPLACEMENT OF THE LCD DISPLAY 55
3.9.4 REPLACEMENT OF INVERTER BACKLIGHT 56
3.9.5 REPLACE THE TOUCH SCREEN CONTROLLER 56
4CALIBRATION AND MAINTENANCE FUNCTIONS 57
4.1 CALIBRATION FUNCTIONS 57
4.2OPTIONS AND EQUIPMENT REQUIRED 59
4.3 CALIBRATION OF SAMPLE TEMPERATURES 59
4.3.1 EXAMPLE OF CREATION OF A NEW CALIBRATION 60
4.3.2 COMMISSIONING A NEW SAMPLE TEMPERATURE PROBE 64
4.4 THE PT 100 TEMPERATURE PROBES INTERNAL TO THE INSTRUMENT 64
4.5 TEMPERATURE MEASUREMENTS BY THERMOCOUPLE 65
4.6 CALIBRATION OF THE BAROMETRIC SENSOR 65

NORMALAB France
2012
N O R M A L A B F r a n c e
4/118
4.7 CALIBRATION OF TEST TUBES 67
4.8 CALIBRATION OF THE TACTILE PAD 68
4.9 MONITORING EXPIRY OF CALIBRATION DEADLINES 68
5DENOMINATION AND FUNCTIONS OF THE ELECTRONIC BOARDS 69
5.1 PROCESS CPU 69
5.2 MMI CPU 69
5.3 CL1 BOARD : 69
5.4 CL2 BOARD : 70
5.5 CL3 BOARD : 70
5.6 CL4 BOARD : 70
5.7 CL56F ET CL 56C BOARDS : 70
5.8 STEPPER BOARD: 71
6SCHEMATIC ELECTRICAL AND ELECTRONIC 71
6.1 INTERCONNECTION SCHEME 71
6.2SPARES PART LIST 73
6.2.1 PROBES AND THERMOCOUPLES 73
6.2.2 FIRST DROP AND FOLLOWER OPTICAL SENSORS 73
6.3 SCHEME OF ELECTRONIC BOARDS 74
6.3.1 CL1 BOARD 74
6.3.2 CL2 BOARD 76
6.3.3 CL3 BOARD 77
6.3.4 CL4 BOARD 78
6.3.5 CL56 BOARD 79
6.3.6 STEPPER MOTOR BOARD 80
6.3.7 DETECTOR PROBE AND DOOR CLOSED DETECTOR SENSOR 80
6.3.8 FRONT PANEL 81
7SPARES PART LIST 83
8TROUBLES SHOOTING 93
9ANNEXE 1 97
9.1 GUIDE TO UPDATE INSTRUMENT 97
9.2 SAFETY RULES 97
9.3 GENERAL CHARACTERISTICS 97
9.4 CONTENT OF NEW VERSION 97
9.5 HOW TO GET A NEW VERSION 97
9.6 HOW TO KNOW THE SOFTWARE VERSION 98

NORMALAB France
2012
N O R M A L A B F r a n c e
5/118
9.7 IMPORTANT RECOMMENDATIONS 98
9.8 ADDITIONAL REQUIREMENTS TO UPDATE YOUR NDI450 INSTRUMENT 98
9.9 PREPARE YOUR USB FLASH DRIVE FOR UPDATING (VIDEO EXAMPLE) 98
9.10 INSTALL A NEW MMI VERSION USING THE UPDATE OPTION (VIDEO EXAMPLE) 100
9.11 INSTALL A NEW FIRMWARE VERSION USING THE UPDATE OPTION (VIDEO EXAMPLE) 103
9.12 ERROR MESSAGES 106
10 ANNEXE 2 107
10.1 LOGBOOK 107
11 ALARM LIST 111
12 NOTES : 117
Version 04-2012

NORMALAB France
2012
N O R M A L A B F r a n c e
6/118
2Structure of the machine
2.1 Mechanical structure
2.1.1 Heating block
2.1.2 Subset compartment

NORMALAB France
2012
N O R M A L A B F r a n c e
7/118
2.1.3 Subset condenser
2.1.4 The ventilation

NORMALAB France
2012
N O R M A L A B F r a n c e
8/118
2.2 Environnement of the machine
The machine must be installed on the stable bench , can supported the weight of the apparatus ( see
characteristics)
It is necessary to respect a minimum environment volume to ensure proper operation and longevity
.
Allow minimum space : 25cm behind and 40 cm on the sides , 100 cm above to ensure adequate
ventilation space.
Do not install the machine near the heating source ( radiator , stove , oven or apparatusl sending hot
air , …), or behing a window receiving the sun

NORMALAB France
2012
N O R M A L A B F r a n c e
9/118
2.3 Electronic structure
2.3.1 Electronic structure
2.3.2 Location of the electronic boards
CL3
board
CL2 board and
Stepper motor
board

NORMALAB France
2012
N O R M A L A B F r a n c e
10/118
CL56F
board
CL56C
board
Inverter pour
backlight
CL56F
board
MMI CPU
board
Touch screen’s
driver
Hard
drive disk
Inverter pour
backlight
CL56F
board

NORMALAB France
2012
N O R M A L A B F r a n c e
11/118
2.3.3 The external connections
2.3.3.1 Keyboard, mouse, printer, monitor, network
Devices type
Port
Video monitor
VGA port on the back side
Keyboard
USB Port on the left side and back side
Printer
USB Port on the left side and back side
Network
Port RJ 45 on the back side
Serial port
Com port on the back side ( 9 pins SubD)
USB key for exportation files
USB Port on the left side and back side
USB key for process restoration
Update port USB
USB Key for MMI or standard update
USB Port on the left side and back side
Power supply
for CPU
Power supply for
stepper motor
CL4 Board
CL1 Board
CPU Process

NORMALAB France
2012
N O R M A L A B F r a n c e
12/118
3Instruction sheets
3.1 Access to parts of the machine
3.1.1 Opening the panels

NORMALAB France
2012
N O R M A L A B F r a n c e
13/118
3.1.2 Removing the front panel
Remove the side and rear panels (see
above procedure 3.1.1)
Remove the compartment door : remove the 4
hinge screws
Remove the 2 drawers :
-Condensates drawer of compartment
-Drawer under heating block
Remove the cap of the expansion tank
Remove the 2 screws
Remove the upper panel
Tools
1 hex head key 2 mm
1 hex head key 2.5 mm
1 hex head key 3 mm

NORMALAB France
2012
N O R M A L A B F r a n c e
14/118
Remove the holding screw on the left side
Remove the 5 screw of the front panel
Remove this holding screw
Remove the 2 black knobs fixing the electronic
drawer
Pull slightly the panel forward
Unplug the ribbon of front panel

NORMALAB France
2012
N O R M A L A B F r a n c e
15/118
Unplug the network cable ( RJ45)
The front panel is free , you can remove it
3.1.3 Access to the electronic drawer
Remove the 2 screws of the upper left panel and
lift the panel on the back
Remove the ground wire

NORMALAB France
2012
N O R M A L A B F r a n c e
16/118
3.2 Level follower
3.2.1 Replacement of the 1rst drop optical sensor
Remove the holding screw
Pull out the optical sensor from the slide
Remove the Jack connector
Plug the connector on the new optical sensor
(Pay attention at the cable to not hinder the
movement of the follower)
Replace the new optical sensor in the slide
Tighten the holding screw
Loosen the locking screw to adjust the optical
position with the adjusting screw
Place a 4mm Ø screwdriver in vertical position
and aligned with the condenser
Read the good position on the maintenance screen
( adjust slowly because the refreshment is slow)
Locking
screw
Holding
screw
Adjusting
screw

NORMALAB France
2012
N O R M A L A B F r a n c e
17/118
3.2.2 Replacement of the follower optical sensor
With the
maintenance
functions ,to do
raise the follower
sensor of 5 cm to
release it from the
follower base
Proceed the same
way as first drop
sensor to remove
the optical sensor
Loosen the
blocking screw and
adjust the optical
sensor position
with the adjusting
screw

NORMALAB France
2012
N O R M A L A B F r a n c e
18/118
3.2.3 Replacement of the limit switches of follower
Tools
1 hex head key 4 mm
1 tubular key 5.5 mm
1 flat blade screwdriver 3.5m
Remove the right panel (see the above procedure 3.1.1)
Position of the low and high sensors
Loosen the maintaining nut of sensor
Release the wires
Extract the sensor ( identify the sense of the
position to replace the new one in the same
sense)
Disconnect the wires from connector of
CL2 board
Low sensor :
-Red 1
-Blue 2
-Black 3
High sensor
-Red 4
-Blue 5
-Black 6
1

NORMALAB France
2012
N O R M A L A B F r a n c e
19/118
3.2.4 Replacement of drip deflector detector
Tools
1 hex head key 3 mm
1 wrench 7mm
Remove the front panel (see above procedure 3.1.1)
Remove the roof of the receiver
compartment(2 hex screws)and extract it
(take care at the heating insulation)
Remove the flange around the condenser
Remove the optical sensor ( without
modifying the position adjustment)
Unplug the optical sensor cable

NORMALAB France
2012
N O R M A L A B F r a n c e
20/118
Remove the 2 maintaining scews
Remove the compartment probe
Lift the probe above condenser
Release the wires and turn the holder around the
condenser ( lift slightly the condenser tube)
Place the holder in front of condenser tube
to access by above
Loosen the maintaining screw
Vis de
maintien
capteur
Capteur