Scientific Systems, Inc. 349 N.
Science Park Road State College, PA 16803 Phone (814) 234-7311 Fax (814) 238-7532 E-Mail [email protected]
Overview
Microprocessor controlled Stepper Motor
Programmable control of highly accurate and predictable motion. Pulsation minimized Pressure compensation controllable Power and speed optimized for flowrate requirements. Noise minimized through motor drive control. Power Supply is less critical in determining motor speed. Low tolerance on motor-to-motor variations.
General Specifications
Power requirements Voltage
48 or 24 volts DC motor drive
24 max volts DC Digital and Analog On board conversion for: 12 volt DC analog 5 volt DC digital 250 mA Digital and Analog MOSFET driven H Bridge ASIC Motor Drive I/O interface to: GAL, Digital, Logic, & Analog I/O
Pump Stop Pump Prime Prime LED Indicator Serial Controlled TTL output 4 position 7 segment LED display
Current Motor Drive
1.5 amp motor drive Series III (A) Series II (B) 80C51 Micro
Digital Control
Communication
RS232 Serial Communication 9600 BAUD 8,1,0
I/O lines for:
Front Panel (connector)
Pump Control Functions
Additional Control Functions:
Power-Up Functions for Series II & III
Keys to Hold Down
UP ARROW & DOWN ARROW UP ARROW & PRIME UP ARROW & RUN/STOP PRIME & RUN/STOP RUN/STOP & DOWN ARROW UP ARROW RUN/STOP PRIME
Routine Enabled
Test Serial Port Test Refill Switch Display Software Version Motor Stall Detector Display Checksum Reset to Factory Settings Select Head Type Set Pressure Compensation
Display
----
or ----
On or OFF
SXX or PXX (pressure / 100)
Circuit Board Layout
Series III
Three board set for high-end control and monitoring
Motor Drive
MOSFET Driven H Bridge dedicated motor drive circuit board.
Motor Drive Board Layout
MOSFET Motor Drive 12 & 5 volt DC Regulators
Digital Motion Control
DC Power Conversion
Microprocessor Control
Digital Control Circuit Board
Control Circuit Board Layout
Interconnect to Motor Drive
RS232 Connection Front Panel Connection
Firmware EPROM
Battery backed RAM
Remaining areas are microprocessor and additional I/O inputs
Analog to Digital Converter
Input for pressure transducer voltage
A/D Converter
Pressure Control (A/D) Board Layout
Voltage Control Calibration Pressure Transducer Input Pressure Calibration Controls
Series I Pump Board
Single board for basic control needs
Motor Drive and Microprocessor Control Layout ASIC Motor Drive. Microprocessor control & additional I/O ports.
Motor Flag
Front panel Connector
RUN, STOP, Frequency
Motor Connection
RS232 Connection
Firmware EPROM
ASIC Motor Drive
Power Input & Control
Troubleshooting
All Boards are Run-In for a minimum of 8 hours (usually overnight). All products are 100% tested in-house.
SSIs field failure rate is extremely low.
Basics
DC Voltage Checks 5 volts, 12 volts, and 36 volt
Series III
Control Board Voltage Test Points
5 volts DC
Motor Drive Board Voltage Test Points Circuit Side of Motor Drive PCB
12 Volt LED Indicator
5 Volt LED Indicator 48 or 24 Volt Test Point Pad and LED Indicator
Series I PCB
Digital Supply Voltage Test Points
5 volts DC
Motor Drive Voltage Test Point
36 volts DC
Power connector for Series I or III Pump Boards ***NOTE **** Series I Pump board has a maximum input voltage of 40 Volts DC on the high voltage drive side of the connector.
DC Powering
5 DC 48 or 24 volt DC 24 volt max
AC Powering
Transformer Secondary AC Input Transformer Secondary Center Tap Transformer Secondary AC Input DC Ground 1 Ground External Capacitor Positive
48 / 24 VDC 24 VDC max 48 / 24 VDC 24 VDC max GND GND
Failure modes
** Warning **
Do not unplug the Motor Connector from the circuit board while the power is on, or has just been turned off. Turn off the power and wait 5 seconds for the voltage present in the capacitors to dissipate. Failure to follow this procedure will damage the motor drive power handling devices.
Pump Not Responding to PC Control. Check RS232 connector Check for 24 / 48 and 5 Volts on the PCB. If 24 / 48 volts isnt present, check the Power Supply connections. If voltage is present at the plug and 5 volts isnt at the test points, replace the circuit board. Replace PCB Series II or Control board on Series III If Pump will not retain initial settings such as in High or Low Pressure Limits or Head size. Replace the battery for the battery backed RAM on the 2 board set Series III.
Motor noise, motor stall, or missing steps at low speed. This is an indicator of: Pressure has built up excessively in the flow path. An over-tightened drive belt. A defective component in the Motor Drive circuits. Motor Drive Diagnosis. If the front panel and/or serial communication works, but the motor wont run, replace the 5 x 20 mm fuse on the circuit board. At low speed the motor may be able to step with only one MOSFET damaged. Run the motor at PRIME or any faster rate, if it stalls its probably a damaged MOSFET. Replace the circuit board.
Flowrate problems All pumps are tested at the factory for flowrate accuracy. Assume that the pump flowed correctly prior to a service call. By nature this is not an electronic problem. Try changing the pressure compensation setting to adjust for your solvents compressibility. Check the fluid path for obstructions that may alter the pressure or flow.
Pressure not functioning correctly Transducer damaged. Usually this will result in a constant maximum pressure reading. Pressure settings that are incorrect can be recalibrated. If in doubt about recalibrating this board, replace the board and Transducer/Pulse Damper with a Factory matched set. Most SSI Pumps maintain a 100 PSI pressure fault window on the upper pressure fault setting. This is maintained so that minor pressure variations from backpressure devices, pulsation, or system setups will not inadvertently trigger the upper pressure fault. If absolute accuracy is needed on the upper pressure fault setting, set the upper pressure fault to 100 PSI less than the systems maximum desired pressure. Damaged PCB. This is a rare case and would require some outside source to damage the unit. Contact SSI customer service for details.
Front Panel connection and operation
Series I Front Panel Connector Series III Front Panel Connector
The 4-digit display shows the pump flow rate (mL/min), or system pressure (PSI), or the set upper or lower pressure limit (PSI) when operating. Choice of display is selected with the MODE key.
Operation Keys
RUN/ STOP: When pressed, this key alternately starts and stops the pump. When pressed, this key increases the flow rate. When pressed, this key decreases the flow rate. PRIME: When pressed the pump runs at the maximum flow MODE : (Series III/PumpA only) Steps through the available controls and readings ML/MIN
o When lit, the digital display shows flow rate in mL/min.
PSI
o When lit, the digital display shows system pressure in PSI.
HI PRESS
o When lit, the display shows the user-set upper pressure limit in PSI.
LO PRESS
o When lit, the display shows the user-set lower pressure limit in PSI. Additional LED indicators
PUMP RUN FAULT
o Lights to indicate that the pump is running. o Lights when a fault occurs and stops the pump.
Fault Conditions and Causes If the pump runs for a short time and then stops, or if it stops unexpectedly: Test for High or Low Pressure Faults or a Stall Fault. Using the Display Panel, run the pump and when the pump stops: The red Fault Light flashes indicating an error has occurred. Series III On a High Pressure Fault the High Pressure LED will light along with the Fault Light, and the pressure will be displayed. On a Low Pressure Fault the High Pressure LED will light along with the Fault Light, and the pressure will be displayed. Series II or III On a Stall Fault only the Fault light is activated, this indicates a motor fault from a lack of power, or overpressure condition.
Power-Up Functions for Series I & III
Additional functions can be accessed by holding specific buttons when the power is cycled on a pump.
Keys to Hold Down
UP ARROW & DOWN ARROW UP ARROW & PRIME UP ARROW & RUN/STOP PRIME & RUN/STOP RUN/STOP & DOWN ARROW UP ARROW RUN/STOP PRIME
Routine Enabled
Test Serial Port Test Refill Switch Display Software Version Motor Stall Detector Display Checksum Reset to Factory Settings Select Head Type Set Pressure Compensation
Display
----
or ----
On or OFF
SXX or PXX (pressure / 100)
Serial Port Loop Back test require a RJ11 connector with Pins 3 & 4 and Pins 2 & 5 connected together. Test Refill Switch will indicate the flag is passed when rotated by hand. This will test the stall fault and fast refill are functioning correctly. Malfunctions are indicated when the display doesnt change. Check that the flag is in the correct connector location. Motor Stall Detector turns off the Stall Fault triggered by missing the flag on the CAM shaft. Reset can be used to determine if a reset to factory settings can correct a problem.
PRESSURE TRANSDUCER CALIBRATION PROCEDURE
Pressure Transducers and component tolerances variations require the circuit board to be matched
to the transducer.
SSI will match replacement Boards to a Transducer/Pulse Damper as a replacement part. In the event a simple adjdutment could correct a problem quickly at a customer sight, the controls
for matching the transducer to a circuit board are included here.
Connect a voltmeter to the pressure board with the black lead on TP11 and the red lead on
TP12. VR2 Max Adjust High Pressure Adjust
VR1 Zero Adjust Pressure Zero Adjust TP 12 PRESS Positive Voltage Test Point TP11 SGND Signal Ground Test Point
Apply power to the pump and verify that the lower pressure limit is 0 PSI and the upper
pressure limit is 6000 PSI. If they are not at these values, change them. With the pump stopped, the prime-purge valve open, and the pump at atmospheric pressure, adjust the Zero Adjust VR1 trimpot until the voltmeter reads approximately 0.000 volts. This can be adjusted to zero just by using the front panel readout, but it is less accccurate. Close the valve and run the pump at 1.00 mL/min. Turn the VR2 Max Adjust trimpot counterclockwise if the pressure readout on the pump approaches 5000 PSI. This will prevent an overpressure fault from stopping the pump. Stop the pump when the test gauge reads approximately 5200 PSI. Another possibility is to use an inline pressure regulator of know fixed pressure value. Run the pump at 1 ml/min and when pressure has stabilized adjust the trimpot to that known, fixed value. Recheck the zero pressure value and the high pressure value, correct as necessary.
Changing the EPROM/Firmware on an SSI Series III style Pump:
Turn off and unplug the pump. Open chassis by removing the 10 screws on the sides of the cover. The EPROM is on the Control PCB.
Control PCB
EEPROM - - tab faces upward - Using an IC remover or suitable device, remove the EPROM. Insert the new EPROM noting that the tab on the EPROM matches the tab on the PCB silkscreen for the IC socket.
NOTE: The Head type must be checked or reset after changing the EPROM.
o Hold the RUN/STOP button while powering the pump. o Use the UP or DOWN arrow keys to set the Head Type
Max Flowrate
100 ml/min heads 24 ml/min heads 12 ml/min heads
Pump Display S50 or P50 S12 or P12 S6 or P6
Notes (Stainless Steel or PEEK respectivly) (Stainless Steel or PEEK respectivly) (Stainless Steel or PEEK respectivly)
Troubleshooting: If the MODE light is lit but the MODE button does not work. The RAM needs to be
cleared. Remove the Battery (see above), wait 1 minute, and turn the pump on. This will reset the RAM. Turn the power off, reinstall the battery and the MODE will be enabled. If the front panel is unresponsive and unlit the EPROM is probably in backwards or improperly seated. Check that the tab on the EPROM matches the tab on the PCB silkscreen for the IC socket. If all lights are lit and the pump is unresponsive, the EPROM may be improperly aligned in the socket. Below is a list of built in functions for SSIs pumps, which are activated by holding specific front panel keys down while turning on the pump. Not all pumps have all these functions. Please call SSI for additional information.
Power-Up Functions for Series III and Dual Piston Pumps
Keys to Hold Down
UP ARROW & DOWN ARROW UP ARROW & PRIME UP ARROW & RUN/STOP PRIME & RUN/STOP RUN/STOP & DOWN ARROW DOWN ARROW UP ARROW RUN/STOP PRIME
Routine Enabled
Test Serial Port Test Refill Switch Display Software Version Motor Stall Detector Display Checksum Select Voltage or Frequency Input Reset to Factory Settings Select Head Type Set Pressure Compensation
Display
On or OFF U or F SXX or PXX (pressure / 100)
For Constant Pressure Pump ONLY
PRIME & DOWN ARROW Set ramp speed factor (% of factory setting 10% to 500%)
For Series I500 and Prep Pumps ONLY
PRIME & DOWN ARROW Pressure Limiting for Pulse Damper (Limits any Pressure above 6100 to 6100 PSI) Pdin --- Maximum Pressure set to 6100 PSI noPd -- Maximum Pressure set to 6100 PSI
For Series IX (Ser III PCB) ONLY
PRIME & DOWN ARROW enabled disabled Pressure Transducer Option Setting (Sets Pressure and Mode Button) Pres --- Pressure Reading & MODE button noPr -- Pressure Reading & MODE button
Series III Control PCB Board Level Information Test Points
Buffered Mtr Flag TP 18 Mtr Flag Input TP7 TP15 12/15 V TP5 +5V TP18 Ext Vin TP16 5 V
TP6 Ground TP3 MTR CLK
TP2 Oscillator TP11 Signal GND TP12 Pressure Voltage
Resistor Selection for Pressure Transducer Scaling
For Transducers Scaled to 6000 PSI upper limits (6142 max reading) use all three resistors, R45, R59, R30. For Transducers Scaled to 10,000 PSI or 2500 PSI upper limits (9999 max or 2512 PSI max reading) and use just two resistors, R45, R30. For Transducers Scaled to 200 PSI upper limits (204 max reading) use just resistor, R45.
R45
R59 R30
Series III Motor Drive PCB Board Level Information
12 V LED
5 V LED
48 or 24 V LED
5 AMP Slo-Blo Fuse
MOSFET Tests
470 470 3 M 3 M 2.7 M
Ever other resistor should have 470 across leads 1 & 3 The remaining MOSFETs should have around 3 M across leads 1 & 3. All MOSFETs should have about 2.7 M across leads 1 & 2.
