Thermo Electron FL40 User manual

FL40 / FL40R Service Manual 89003568 Page 1 of 43
FL40 / FL40R
Centrifuges
SERVICE MANUAL
89003568
CAREFULLY READ THIS MANUAL AND THE OPERATING MANUAL
BEFORE REPAIRING YOUR INSTRUMENT
THIS DOCUMENT IS PROPERTY OF THERMO ELECTRON CORPORATION
it may not be duplicated or distributed without the owner's authorisation
The validity of the guarantee is subject to the observation of the
instructions and precautions described in this document

REVISION STATUS
FL40 / FL40R Service Manual 89003568 Page 2 of 43
INDEX DATE AMENDED PAGES NOTES
a 24/03/2004 Initial release

WARRANTY
FL40 / FL40R Service Manual 89003568 Page 3 of 43
THERMO Electron Corporation guarantees that this unit is free from defects in materials and
workmanship when it leaves the factory and undertakes to replace or repair the unit if it proves defective
in normal use or during service for a period of ONE YEAR from the delivery.
Our liability under the guarantee is limited to repairing the defective unit or any part of the unit providing
it is sent, postage paid, to an authorized service centre or the SAINT-HERBLAIN office.
This guarantee is invalid if the unit is incorrectly used, poorly serviced or neglected, mis-used or
accidentally damaged.
There is no explicit guarantee other than as stated above.
For further information, assistance or service :
Technical Service Address
North America: [phone]
Europe: Austria [phone]
Belgium [phone]
Finland [phone]
France [phone] or [phone]
Germany [phone] or [phone]
Italy [phone]
Netherlands [phone]
Russia/CIS [phone]
Spain/Portugal [phone]
Switzerland [phone]
UK/Ireland [phone]
Asia: India [phone]
Japan [phone]
China [phone] or [phone]
Other Asian countries [phone]
Countries not listed: [phone] or
33 2 28 03 20 00

CONTENTS
FL40 / FL40R Service Manual 89003568 Page 5 of 43
1. INTRODUCTION.................................................................................................................... 7
1.1. PURPOSE.....................................................................................................................................7
1.2. PRESENTATION........................................................................................................................7
1.3. SPECIFICATIONS......................................................................................................................8
1.3.1. Dimensions and weight............................................................................................................................8
1.3.2. Electrical Specifications...........................................................................................................................8
1.3.3. Performance .............................................................................................................................................8
1.4. INSTALLATION PROCEDURE...............................................................................................9
2. THEORY OF OPERATION.................................................................................................. 10
2.1. DESCRIPTION..........................................................................................................................10
2.2. COMPONENT LAY-OUT........................................................................................................10
2.3. MOTOR CONTROL PRINCIPLE..........................................................................................12
2.3.1. Introduction............................................................................................................................................12
2.3.2. The motor...............................................................................................................................................12
2.3.3. Power control.........................................................................................................................................13
2.4. ELECTRONICS - STRUCTURE.............................................................................................14
2.4.1. Introduction............................................................................................................................................14
2.4.2. Microprocessor + Power pcb..................................................................................................................14
2.4.3. Imbalance sensor....................................................................................................................................16
2.4.4. Tacho sensor...........................................................................................................................................16
2.4.5. Temperature sensor (FL40R) .................................................................................................................16
2.4.6. Refrigeration control board (FL40R).....................................................................................................16
2.4.7. Input - Output.......................................................................................................................................17
3. DIAGNOSTICS AND REPAIRS...........................................................................................18
3.1. INTRODUCTION......................................................................................................................18
3.2. FUNCTIONAL TEST ...............................................................................................................18
3.2.1. Eprom version........................................................................................................................................18
3.2.2. Test mode...............................................................................................................................................18
3.3. FAULT CODES.........................................................................................................................21
3.4. TROUBLESHOOTING CHART.............................................................................................22
4. REPLACEMENT PROCEDURES .......................................................................................24
4.1. MOTOR REPLACEMENT......................................................................................................24
4.1.1. Unrefrigerated model FL40....................................................................................................................24
4.1.2. Refrigerated model FL40R ....................................................................................................................25
4.2. IMBALANCE DETECTOR REPLACEMENT .....................................................................26
4.3. REPLACEMENT OF THE LID LOCK ASSEMBLY...........................................................26
4.4. LID LOCK ASSEMBLY ELEMENT REPLACEMENT......................................................27
4.4.1. Lid lock microswitch replacement.........................................................................................................27
4.4.2. Lock solenoid microswitch replacement................................................................................................27
4.4.3. Solenoid replacement.............................................................................................................................28
4.5. POWER SUPPLY RACK REPLACEMENT.........................................................................28
4.5.1. Dismounting...........................................................................................................................................28
4.5.2. Refitting .................................................................................................................................................28
4.5.3. Refrigeration board (FL40R) replacement.............................................................................................28

CONTENTS
FL40 / FL40R Service Manual 89003568 Page 6 of 43
4.6. ELECTRONIC BOARD REPLACEMENT...........................................................................29
4.6.1. Microprocessor + Power pcb..................................................................................................................29
4.6.2. Display board.........................................................................................................................................30
4.7. KEYBOARD AND BLUE WING REPLACEMENT ............................................................30
4.8. GAS SPRING REPLACEMENT.............................................................................................30
4.9. EPROM REPLACEMENT.......................................................................................................31
4.10. LID REPLACEMENT ..............................................................................................................31
4.11. REFRIGERATION SYSTEM REPAIRS (FL40R)................................................................32
4.11.1. Refrigeration SYSTEM replacement.................................................................................................32
4.11.2. Condenser components replacement .................................................................................................33
4.12. Motor checking...........................................................................................................................33
5. SPARE PARTS....................................................................................................................... 34
5.1. FL40 GENERAL SCHEMATIC..............................................................................................34
5.2. FL40R AND GENERAL SCHEMATIC..................................................................................35
5.3. MOTOR......................................................................................................................................36
5.4. LOCK..........................................................................................................................................37
5.5. ELECTRONIC RACK..............................................................................................................38
5.5.1. Rack FL40..............................................................................................................................................38
5.5.2. Rack FL40R...........................................................................................................................................38
5.6. FRONT PANEL.........................................................................................................................39
5.7. COOLING UNIT (FL40R)........................................................................................................39
6. WIRING DIAGRAM.............................................................................................................. 40
5.1. WIRING DIAGRAM FL40 120V ............................................................................................40
5.2. WIRING DIAGRAM FL40 230V ............................................................................................41
5.3. WIRING DIAGRAM FL40R 120V .........................................................................................42
5.4. WIRING DIAGRAM FL40R 230V .........................................................................................43

C4i / FL40R / GT4i Service Manual 89002861 - 7 -
1. INTRODUCTION
1.1. PURPOSE
This manual contains maintenance instructions intended for use by a qualified maintenance
or service technician. It is organized to provide maintenance personnel with basic data on
the theory of operation to assist in troubleshooting. Moreover, it outlines parts replacement
and calibration procedures for putting the centrifuges back into service.
Should a specific maintenance problem arise which is not covered in this manual, please
ask the authorized service organization in your area for assistance, or contact our sales
department :
THERMO AFTER SALES SERVICE
10 Rue Duguay Trouin
44807 SAINT HERBLAIN
Tel : [phone]
Fax : [phone]
1.2. PRESENTATION
The FL40, FL40R (refrigerated) centrifuges are instruments designed for laboratory use.
Using relative centrifuge force (RCF) allows elements of different density to be separated.
The rotor is the main load. A swing-out design allows a higher load than does an angle
design. The larger the rotor diameter is, the higher the load can be and thus the slower the
speed will be.
The RCF is directly proportional to the radius of sedimentation and to the square of the
speed.
The gas used in the refrigeration system (FL40R) is R130a, without CFC, recommended
by the applicable directive for protection of the ozone layer.

FL40 / FL40R Service Manual 89003568 Page 8 of 43
1.3. SPECIFICATIONS
1.3.1. DIMENSIONS AND WEIGHT
Dimensions (H x W x D) FL40 : 66 x 58 x 86 cm FL40R : 66 x 58 x 86 cm
Packed (H x W x D) FL40 : 78 x 68 x 100 cm FL40R : 78 x 68 x 100 cm
Weight – uncrated / crated FL40 : 95 kg / 120 kg FL40R : 115 / 145 kg
1.3.2. ELECTRICAL SPECIFICATIONS
Mains supply 220/240 VAC 50 Hz Mains supply 120 VAC 60 Hz
FL40
FL40R
11177560
11177563
FL40
FL40R
11177561
11177564
Max power FL40 : 1200 W FL40R : 1500 W
Average power FL40 : 700 W FL40R : 1400 W
Refrigeration FL40R : 700 W
1.3.3. PERFORMANCE
Max speed Swing-out : 5400 rpm (FL40) Angle : 7800 rpm (FL40)
Swing-out : 5400 rpm (FL40R) Angle : 8000 rpm (FL40R)
Max RCF Swing-out : 3800 x g (FL40) Angle : 9862 g (FL40)
Swing-out : 4800 x g (FL40R) Angle : 10375 g (FL40R)
Max capacity Swing-out : 4 x 750 ml Angle : 8 x 100 ml
Microprocessor controled
Display High visibility digital display
Memory size 5 programs, direct access
Program protection Recall key lock
Speed Range 500 to 8000 rpm
Step 10 - 100 rpm
Accuracy ±20 rpm
Timer Range 30 sec to 99 min + hold position
Step 30 sec to 1 min
Acceleration rates 5
Bracking rates 5
Temperature
FL40R Range -9°C to +40°C CT -9°C to +6°°C
Step 1°C 1°C
Accuracy ±1,5°C ± 1.5°C
Typical performance 4°C at 4500 rpm (4 x 750ml swing-out) CT 4°C at 4300 rpm
1°C at 7800 rpm (30 x 1,5 ml angle) ± 1.5°C
Max density 1,2 g/cm3
Max energy 14 400 J
Radius Range 64 to 178 mm
Step 1 mm

FL40 / FL40R Service Manual 89003568 Page 9 of 43
1.4. INSTALLATION PROCEDURE
The environment must not be dusty or corrosive.
The bench top must be of a rigid construction capable of supporting the weight of the centrifuge, not to
transmit vibrations.
IMPORTANT : at least two people are required to lift the centrifuge from the palette and place it on the
bench.
WARNING : The rear palette of the instrument must be at least 30 cm from the walls to allow hot air
from the condenser to escape. To avoid the proximity of heat sources.

C4i / FL40R / GT4i Service Manual 89002861 - 10 -
2. THEORY OF OPERATION
2.1. DESCRIPTION
The microprocessor system which controls the FL40 and FL40R centrifuges ensures the
operation of the following major elements:
- Management of the operating modes,
- Generation of alternating current amplitude and frequency,
- Adjustable components for the motor speed servo,
- Management of the acceleration and braking profile/rates,
- Management of the temperature regulation (FL40R),
- Management of the safety devices :
. Lid lock
. Zero speed detection
. Imbalance detection
. Motor over temperature detection.
- Management of fault diagnosis
2.2. COMPONENT LAY-OUT
The input and control devices are located on the front panel and are comprised of a
membrane keyboard and three digital displays.
Everything is controlled by a 16 bit microprocessor. The control program of the centrifuge is
stored in an EPROM.
Data are conveyed into a dynamic RAM and are saved even when the power is down, thanks
to an internal battery, which supplies power.

FL40 / FL40R Service Manual 89003568 Page 11 of 43

FL40 / FL40R Service Manual 89003568 Page 12 of 43
2.3. MOTOR CONTROL PRINCIPLE
2.3.1. INTRODUCTION
The FL40 / FL40R family of centrifuges is fitted with an asynchronous 3 phases motor. During
centrifugation, the microprocessor generates a system of sinusoidal 3 phases voltages variable in
amplitude and frequencies. During the braking phase the energy from the rotating parts is
commuted across a resistance.
2.3.2. THE MOTOR
The motor is comprised of a 3 phases stator and a short-circuited rotor.
When correctly powered, the stator creates a magnetic field rotating at the synchronised speed
Ns :
Ns = F/p
F : supply frequency
P : number of pairs of poles of the motor
The rotating field generated in the motor induces e.m.f.'s. These e.m.f.'s produce currents in the
short circuited rotor.
These induced currents found in the magnetic field create forces opposed to those which induced
them.
It is the relative speed between the rotor and stator which is the cause of these induced currents,
thus the forces will reduce this relative speed by driving the rotor at a speed close to that of the
fields created at the stator.
The difference (s) between the synchronised speed Ns and the actual speed N of the rotor is
called the slippage.
s = Ns - N
Ns
At a given frequency, the slippage value depends on the resisting torque (i.e. that of the rotor).
Rotor
Stato
r

FL40 / FL40R Service Manual 89003568 Page 13 of 43
2.3.3. POWER CONTROL
It is necessary to supply, from a single phase mains supply (230 V - 50 Hz or 120 V - 60 Hz),
three variable tensions with amplitude and with frequency, dephased by 2π/3.
The voltage is rectified then filtered by C to supply the constant voltage +E. The value of the
capacitor C is high.
For a 230V – 50 Hz mains supply E = 230 √2 = 325 V
C = 1000 µF / 400 V
The 6 transistors act as switches (open or closed).
These transistors commute at a fixed frequency (8 kHz).
To affect the voltage at T we act upon the commands of the transistors a and b, b always being
the opposite to a (a = closed, b = open). By changing the cyclic ratio (closed/open) we obtain a
mean sinusoidal value so we are able to vary the amplitude and frequency.
The pilot frequency must be elevated compared to the frequency of the generated sinusoidal
voltage. The latter is around 400 Hz at 24000 r.p.m. (f pilot / f sin = 10 at max. speed).
In the same way, the voltages at points R and S will be sinusoidal between OV and +E and
dephased by 2π/3 between them.
These 3 voltages are simple voltages varying between OV and +E. They are partly sinusoidal
and partly on a baseline situated at +E/2. Thus the O of the sinusoidal voltage corresponds to 50
% of the cyclic ratio.
The voltages applied to the rotor phases are the compound voltages VR-VS,VS-VT, VT-VR and
will vary between +E and –E (0-(+E) = -E).
Thus the voltages with amplitude close to that of the mains are reproduced at the motor
terminals.
Speed synchronisation is directly proportional to the frequency of the voltage supplied to the
motor.
Ns = fx 60 (for a 2pole motor).
The motor rotates at a speed N below the speed Ns.
Ns – N = SLIPPAGE (the slippage varies between 1 and 3 %).
Ns
E
0
+
S
T
AR
B
C

FL40 / FL40R Service Manual 89003568 Page 14 of 43
To vary the speed, it is necessary to vary NS and thus the frequency of the voltage supplied to
the motor.
The torque characteristics will be translated on the speed axis. The supply voltage will vary from
O to 4000 r.p.m. in order to keep the U/f ratio constant and not saturate the magnetic circuit.
2.4. ELECTRONICS - STRUCTURE
2.4.1. INTRODUCTION
The electronic part of the apparatus consists of two boards : the microprocessor + power pcb,
where every function is located and the user interface pcb with display, and LEDs. The former is
located inside the body of the machine, the second behind the front panel.
The electronic imbalance sensor is located on the motor stabilizer and allows the detection of
excessive imbalance due to the rotor loading.
2.4.2. MICROPROCESSOR + POWER PCB
On the microprocessor + power pcb, 3 distinct zones can be identified, whose functions are
described below. Each zone has its own independent power supply.
Vitesse
Couple
résistant
Couple
Speed
Torque

FL40 / FL40R Service Manual 89003568 Page 15 of 43
ZONE 1
This zone includes the microprocessor, the EPROM containing the software and the non-volatile
RAM containing the program parameters.
The set of components in this zone is at the potential of the microprocessor : 5 VDC.
ZONE 2
This zone ensures the conformity of the signal type coming from the different detectors before
their arrival at the microcontroller via opto couplers. It also monitors the lid lock control and
refrigeration group command.
The power supply for this zone is 12 VDC.
The different signals coming to this zone are :
- Bowl temperature
- Signal coming from the imbalance sensor
- Tacho signal
- Lid position signal
- The motor overtemperature and the lid solenoid control
ZONE 3
WARNING : THIS ZONE IS AT MAINS VOLTAGE

FL40 / FL40R Service Manual 89003568 Page 16 of 43
This zone, isolated from the microprocessor part by opto-couplers, is the electronic part related
to the power in the system. This zone includes :
- The 15 VDC power supply for the control electronics for this zone.
- The control circuit of the 6 basic signals of the IGBT module.
- The 3 PWM commands coming from the microcontroller.
- The command of activation of the module of power coming from the micro-controller.
- The brake GBT with the command which permits flow through the braking resistor.
- The diode bridge which, from the mains, charge the capacitor of the continuous bus.
- The relay which, controlled by the supply of power, then short circuits the resistance of the
charge of the capacitors of the continuous bus a few moments after switch-on.
- The module of 6 IGBTs and its heat sink which power the motor.
2.4.3. IMBALANCE SENSOR
As described in the introduction, this sensor allows the detection of an excessive imbalance in
the rotor loading.
The device amplifies vibrations due to the imbalance and generates a signal beyond a preset
threshold.
After shaping, this signal is sent to the microprocessor for the safety devices.
2.4.4. TACHO SENSOR
The tacho sensor is comprised of an optical sensor, which generates two pulses per revolution.
2.4.5. TEMPERATURE SENSOR (FL40R)
The sensor is a double thermistance. It delivers a signal proportional to the temperature.
2.4.6. REFRIGERATION CONTROL BOARD (FL40R)
The board controls the power signal to the refrigeration group.

FL40 / FL40R Service Manual 89003568 Page 17 of 43
2.4.7. INPUT - OUTPUT
Imbalance detection
Towards display board Alim face
Alim Alim
Termal
p
robe
Tachy hall
Temp. motor
Alim. 24
Switch electro
Switch lock
Electro
Order goup
Sector
power
Diodes
version
120V
R Brake
Motor
Contactor

FL40 / FL40R Service Manual 89003568 Page 18 of 43
3. DIAGNOSTICS AND REPAIRS
3.1. INTRODUCTION
The FL40, and FL40R are equipped with a diagnostic menu in order to help locate possible
breakdowns. The possible conditions of malfunction are communicated to the user by means of
error codes on the display and buzzer alarms.
3.2. FUNCTIONAL TEST
Certain functional tests can be done directly using the keyboard and display.
These tests must only be undertaken by someone qualified to do so. They are protected by an
access code.
3.2.1. EPROM VERSION
The first message that appears when the machine is switched on remains active for a few
seconds (machine set up).
Nota : with the older EPROM version "JOUAN" is displayed instead of "88888".
3.2.2. TEST MODE
This mode is accessible by using a combination of keys while the machine is setting up (at
power ON).
Press on the following two keys at the same time :
Acceleration programming key Braking programming key
. 0 3 0
. A
J O U A N
"88888" underneath which is a two figure number (in the timer display)
indicating the type of EPROM fitted to the centrifuge :
Example : 30 = C4i
The EPROM index letter is identified on the temperature display.
8 8 8 8 8

FL40 / FL40R Service Manual 89003568 Page 19 of 43
Test 1 : Miscellaneous test
0 0 0 0 0 5 digits display : speed read
T - 1 3 digits display : T-1 for Test 1
2 0 2 digits display : actual temperature
Tachometer test :
Turn the rotor by hand : the speed should appear on the 5 digits display.
Lid solenoid test :
Press on the key corresponding to program 2 to power and/or release the solenoid.
Resetting of the 5 programs :
Keep pressing on the key corresponding to program 4.
Complete program resetting on RAM :
Press simultaneously on the Δspeed programming key and the PULSE key to allow
complete resetting of the machine when it is next switched on.
-Press START to pass to the next test
-Press STOP to leave the test mode
Test 2 : Run linking
This test safety used in the factory, starts a series of preset runs after having pressed the
pulse key :
C Y C L E Run cycles of the selected program can be run with a one
minute pause between each
- - -
6 Press Δand ∇to change the number of runs from 1 to 99
Cycles won't start if cycles number is less than 3.
During the run, when rotating, displays are the same as they would be outside the test
mode.
Between two runs (1 minute pause) displays are :
C Y C L E
0 0 0 Reserved for factory testing
2 Next run number
-Press START key to go to the following test
-Press STOP key to exit from the test mode

FL40 / FL40R Service Manual 89003568 Page 20 of 43
Test 3 : Statistical analysis
S T A T S Press Δand ∇to scroll on the 5 digit display
- - -
0 1 : running hours total (x 100)
2 : total number of runs
3 : number of hours above 5000 rpm
4 : number of runs above 5000 rpm
-Press START key to go back to test 1
-Press STOP key to exit from the test mode