You are on page 1of 20

SERVICE MANUAL

Shaking Water Bath

SW-21C

ACTUELSET R . P . M . ALARM

C / R.P.M.

SET R.P.M.

20 ... 90 C 40 ... 200

SW-21 C

JULABO Labortechnik GmbH


D-77960 Seelbach / Germany
( +49-7823 / 51-0
Printed in Germany 3 +49-7823 / 2491
Changes without prior notfication reserved
E-Mail: info@julabo.de
1.961.4040SE1 - 05/99
Internet: http://www.julabo.de
2
SW-21C

Table of contents

1. Description.......................................................................................................... 5

2. Operating controls and functional elements........................................................... 6

3. Spare parts list .................................................................................................... 7

4. Circuit description............................................................................................... 10

4.1. Power distribution and motor control board................................................ 10

4.2. Control board ............................................................................................ 11

4.3. Display board ............................................................................................ 13

5. Component disassembly...................................................................................... 14

6. Calibration procedure.......................................................................................... 17

7. Circuit and component mounting diagrams............................................................ 20

3
4
SW-21C
1. Description

The JULABO SW-21C Shaking Water Bath is equipped with a stainless steel tank for the bath
liquid (water).
An electronic, proportional temperature control automatically ensures optimum heat-energy supply
for varying requirements. Thus rapid heating and a high temperature stability are achieved.
A circulating pump ensures optimum temperature distribution in the bath.
A shaking carriage supported on rollers is moved by a geared DC Motor via a pushrod. The motor
drive electronics enables the shaking frequency to be adjusted.
The setpoint temperature, safety temperature value or shaking frequency can be displayed
intermittently with the actual bath temperature on the LED display.
For applications near ambient temperature the cooling coil can be integrated in a cooling loop.

IMPORTANT:

F
Repairs are to be carried out only by qualified service personnel authorized by
JULABO LABORTECHNIK GMBH.
Repaired equipment must comply with the quality standards specified by
JULABO LABORTECHNIK GMBH.

When placing an order for spare parts the following details should be included:
* Version and serial number (indicated on the identification plate on the rear of the unit)
* Part order number, description, and required quantity (refer to the mechanical drawing
and the spare parts list)

5
Operating controls and functional elements

2. Operating controls and functional elements


1 Mains switch, illuminated
2 Temperature selector dial
3 MULTI-DISPLAY, LED digital temperature and
shaking frequency indication
4 Selector switch for MULTI-DISPLAY
5 Heater control light
6 Alarm control light
7a Safety temperature adjustment screw
7b Indication of safety temperature (on MULTI-DISPLAY)
8a Shaking frequency selector dial
8b Indication of shaking frequency (on MULTI-DISPLAY)
9 Indication of setpoint temperature (on MULTI-DISPLAY)
10 Indication of actual temperature (on MULTI-DISPLAY)

16 Shaking carriage
17 Insert tray for Erlenmeyer flasks or test tube racks
18 Thumb screw for shaking tray insert (4 pcs)
19 Pushrod with holding screw
20 Drain plug
21 Cooling coil connections

21

20

6
SW-21C
3. Spare parts list

7
Spare parts list

Pos. No. Description Order-No.

1.10 Control board SW-21C 7.503.5730


IC1 4xNAND, CMOS 4011 5.136.4100
IC2-IC4 OP-Amplifier, MC 4741 5.136.0350
P1 Precision trimmer, 10 K 5.315.1200
P2-P5 Precision trimmer, 500 Ohm 5.315.1300
SG1 Piezo buzzer, type SM 4 5.327.0200
1.12 Display board 7.509.5731
IC1 A/D converter 5.136.4220
IC2 4xNAND, CMOS 4011 5.136.4100
A1-A4 7-segment display, green 5.136.3250
P1 Precision trimmer, 500 Ohm 5.315.1300
P2 Precision trimmer, 10 kOhm 5.316.0100
P3 Precision trimmer, 10 kOhm 5.315.1200
P4 Precision trimmer, 2 kOhm 5.315.1100
P5 Potentiometer, 10 kOhm 5.312.1000
P6 Ten-turn potentiometer, 10 kOhm 5.311.0160
S1 Rotary switch 5.324.0410
1.13 Power distribution and motor control board 220 V 7.501.5730
Power distribution and motor control board 115 V 7.501.5740
TR1 Transformer 115/220 V 5.161.0500
SI4 Temperature fuse 105 C 5.150.0120
ZVS1 Optocoupler, MCP 3043 5.136.3043
IC4 Puls width regulator, LM 3524 N 5.136.4600
T1 PNP Darlington transistor, BD 898 5.120.1050
REL1 Relay 24 V/10 A 5.326.0051
1.14 Triac BTA 25-700B 5.122.0200

1.16 Mains switch, illuminated (green) 220 V/115 V 5.322.0050


Mains switch, illuminated (yellow) 115 V 5.322.0110
1.18 Microfuse 10 A/mtr 5.152.0450

1.19 Microfuse 1.6 A/mtr 5.152.0260

1.20 Power cord guide 5.352.3100


Counternut 5.352.0110
Power cable 230 V (European standard) 5.350.3150
Power cable 250 V (Swiss standard) 5.350.4150
Power cable 115 V (USA standard) 5.350.5130
1.22 DC gear motor 24 V 6.624.0250

8
SW-21C
Pos. No. Description Order-No.

1.23 Pump motor 220 V/50 Hz 6.630.2050


Pump motor 115 V/60 Hz 6.630.1050
Viton tubing (10 mm inner dia / 2 x 150 mm long) 3.460.2300
1.24 PTC sensor, 135 mm long 7.118.5650
Miniature plug, 4-pole for PTC sensor 5.336.0410
Spring for sensor 4.360.5660

1.28 Heater coil: 220 V / 2000 W 6.605.0440


115 V / 1000 W 6.605.2420
1.40 Light barrier GP1A05 5.136.2510

1.42 Level switch 5.322.8200

2.10 Guide roll 7.142.0500

2.12 Oval screw, M5x10 3.162.0510

2.14 Clip (safety sensor to heater coil) 4.360.5650


2.17 Cooling coil 7.150.5650

2.18 Operating panel SW-21C 6.600.5650

2.20 Rotary knob (6 mm dia.) 5.302.0150


Nut cover without pointer 5.302.0110
2.22 Rotary knob (4 mm dia.) 5.302.0170
Nut cover with pointer 5.304.0100
Cover for Pos. No. 2.20 and 2.22 5.308.0100
2.26 Drain plug 7.130.0100

2.28 Rubber foot 3.450.0100

2.32 Swivel head 3.472.0010

2.34 Pushrod, complete 7.100.1002

2.36 Bearing sleeve 3.476.0810

2.38 Holding screw 4.140.0900

2.40 Ribbed boot 3.454.0510

9
Circuit description
4. Circuit description

4.1. Power distribution and motor control board


Part No. 7.501.5730
The mains voltage is applied to clamp connector SV2 and from there - via the mains fuses Si1/Si2
and the external mains switch - to mains transformer TR 1 and relay Rel 1. The mains transformer
features three secondary windings.
a) The bridge rectifier GR 1 supplies an unregulated voltage of
24 V DC which is applied to capacitors C4 and C5 for smoothing. This voltage serves as
operating voltage for the DC shaking mechanism controlled by the motor controller consisting of
IC1 and T1.
The motor controller functions as digital PWM circuit (pulse width modulator) with series current
coupling for constant speed. T1 operates as electronic switch, diode D2 is free running, and the
motor functions simultaneously as memory inductance. During the off time of T1, the motor
current is maintained via the inverse motor EMF through diode D2. The motor current results in
a current proportional voltage drop across R19. This voltage is smoothed by R6 and C15 and
then applied to pin 1 of the controller amplifier via coupling resistor R7. The motor voltage mean
value is derived from the integrator element formed by R14 and C21. Through R13 this voltage
is then likewise applied to pin 1 of the controller. R11 functions to compensate the no-load
losses of the motor. The nominal speed value is applied to pin 2 of the controller ( nominal
value motor controller: controller board 7.503.5730 and display board 7.509.5731).
The voltage drop across R19 serves also as signal for the integrated over-current limiter circuit.
The signal voltage is delayed by R8 and C17 and then applied through R9 to pin 5 of IC 1.
The operating frequency of the oscillator (approx. 20 kHz) is determined by R10 and R18. A
positive signal on pin 10 switches off the controller.
b) The stabilized supply voltage of + 5 V for the A/D converter on the display board is derived
from GR2 and IC2.
c) A positive and negative voltage of approx. 24 V with respect to 0 V is derived from rectifier
GR3. The positive voltage serves as supply voltage for alarm relay REL1, the zero voltage
switch ZVS1 and the voltage stabilizer IC3, which in turn supplies the +15 V operating voltage
required by the controller electronic.
Potentiometer P1 serves exact adjustment of the +15 V supply voltage which is used also as
reference voltage for the controller electronics. The negative 24 Volts are applied to IC4 to
obtain a stabilized -15 V. This voltage serves also as supply voltage for the controller
electronics.

10
SW-21C

Capacitors C2, C3, C7, C8, C9, C11, C13, C14 and C23 suppress any AC interference
voltage with which the supply voltages may be burdened.
The electrolytic capacitors C3, C4, C6, C10 and C12 smoothen the rectified voltage.
In case of an alarm condition, REL1 causes a complete shutdown of the circulator pump and
heater. The current compensated filter formed by DR1 and C1 ensures that no high-frequency
noise from the motor is induced in the supply voltage circuits.

4.2. Control board


Part No. 7.503.5730
Operating circuit
The operating temperature is measured by an internal working temperature sensor (A-sensor:
KTY11; 2 kOhm at 25 C) and evaluated inside the operations amplifier IC2 (pins 1, 2 and 3). The
signal output consists of a temperature-dependent, linear voltage of 0 V = 0 C with a slope of 10
mV/K.
P3 serves adjustment of the output voltage on MP 6 to 0 V at 0 C, while P2 is used to adjust the
slope of the output voltage.
The actual measured value and the adjusted setpoint value (from pins 5, 6 and 7 of operations
amplifier IC3) are applied through resistors R49 and R48 to the differential amplifier IC2 (pins 5, 6
and 7) for obtaining the differential voltage between the setpoint value and the actual value. The
differential control voltage is available on MP4. The internal amplifier circuits of IC2 (pins 8, 9, 10,
and 12, 13 and 14) function as PI (proportional/integral) stages.
The internal operating amplifier circuits of IC3 (pins 12, 13, 14 and 8, 9 and 10) function as
triangular (delta) voltage generator.
By superimposing the differential voltage (voltage difference between setpoint value and actual
value) on the triangular voltage, a PWM signal is obtained at the output of the PI stage. The
amplitude of the difference signal determines the pulse-to-interval ratio of the PWM signal. Through
diode D8 and resistor R43 the PWM signal drives the base of transistor T8. The amplified PWM
signal is then tapped off at pin 1 of SV2 for driving the zero voltage switch ZVS1 ( power supply
board/ZVS1). The PWM signal is used as quasi proportional drive signal for the heater circuit.

Nominal value motor controller


IC3 (pins 1, 2 and 3) functions as comparator for switching off the motor. When the voltage
determinating the nominal speed drops below 1.94 V, the output signal of the comparator turns
negative and T1 switches off the collector current. This dependably switches off the motor
controller at low nominal voltage levels.

11
Circuit description

Speed control
A fork-type light barrier connected to SV3 monitors the speed. The open collector output is
connected to pin 3. R60 serves as load resistance and IC 1 (pins 8, 9 and 10) functions as pulse
inverter. The clock pulses are available on pin 4 of SV2.

Safety circuit
The safety temperature is measured by an internal safety temperature sensor (S-sensor: KTY11; 2
kOhm at 25 C) and evaluated inside the operations amplifier IC4 (pins 1, 2 and 3). The signal
output consists of a temperature-dependent, linear voltage of 0 V = 0 C with a slope of 10 mV/K.
P5 serves adjustment of the output voltage on MP 7 to 0 V at 0 C, while P4 can be used to adjust
the slope of the output voltage.
The difference voltage between the working and safety temperature sensors is obtained from IC4
(pins 12, 13 and 14). When the temperature detected by the working temperature sensor is more
than 15 C higher than the temperature detected by the safety temperature sensor, T6 is switched
conducting and causes an alarm. The difference voltage is coupled through R19 to inverter IC4
(pins 8, 9 and 10), whose output signal switches T5 conducting on reversed conditions, likewise
activating an alarm.
IC4 (pins 5, 6, and 7) constitutes an adjustable comparator circuit.
The nominal safety value is applied to Pin 7 of SV2 and coupled through R26 to pin 6 of
comparator IC4. When the voltage on MP7 exceeds the nominal safety value, the output of the
comparator is connected to the positive supply voltage and drives transistor T7 conducting.
IC1 (pins 4, 5, 6, and 11, 12 and 13) functions as self-exited trigger circuit with a delayed response
time. All monitor functions have equal priority and can trigger an input alarm via the collector
circuits of T4 to T7.
At normal operation T3 is driven conducting through R7, thereby closing the alarm relay circuit (
power board REL1).
In case of an alarm condition, the connection between the emitter of T8 and the collector of T3
blocks the drive signal for the heater circuit via the triac and the zero voltage switch.
The alarm signal is inverted in IC1 (pins 1, 2 and 3) and then used to drive transistor T2 via
coupling resistor R6. The collector of T2 drives the buzzer, which can be switched off with S1. The
same signal is applied to pin 3 of SV2 for driving the alarm indicator LED6.

12
SW-21C

4.3. Display board


Part No. 7.509.5731
Nominal value signal transmission for speed control and the working and safety
temperature circuits
P5, R29, R28 and R27 form the nominal value speed control circuit for the motor controller.
Setpoint temperature control of the working circuit is effected with components P4, R20, R21,
R22 and the external potentiometer.
P4 serves adjustment of the max. adjustable setpoint value.
Setpoint temperature control of the safety circuit is effected with components P2, R10, R11 and
R12.

Speed evaluation
Speed evaluation is performed by IC2. The pulses detected by the fork-type light barrier are
converted to needle pulses in the differentiating circuit formed by C11 and R17. The two internal
gates of IC2 (pins 1, 2, 3 and 8, 9, 10) function as monostable flip-flop stage. Each pulse on pin 4
of SV1 triggers a pulse of defined length. The pulses are predicated in IC2 (pins 11, 12, 13). The
mean value of the pulse signal is formed by the RC combinations R16/C10 and R15/C9. This
output voltage is proportional to the motor speed and applied to the voltage divider R13/R14 for
matching to the input voltage range of the A/D converter.
P3 serves adjustment of the digital display at maximum motor speed.

A/D converter
IC1 functions as A/D converter with integrated LED drivers for the 7-segment indicators A1, A2,
A3 and A4. The module requires a voltage of + 5VD and a stabilized negative voltage of -6.8 V.
This negative voltage is obtained from ZD1. The reference voltage for the converter is adjusted with
a voltage divider consisting of R9, P1 and R8. P1 serves to adjust the slope of the converter.
Switch S1 is used to select the various signal sources and the corresponding LED indicator LED1,
2, 3, or 4 on the front of the equipment.
Transistor T1 drives the decimal point to the left of the last digit. When speed indication has been
selected a positive voltage on the base of transistor T1 blocks the transistor and thus suppresses the
decimal point.
C13 and C14 block high frequency noise from the supply voltage circuits. R23 and C15 form a
ground reference point for the controller electronics with reference to the earthed neutral conductor.

13
Component disassembly

5. Component disassembly

Take care that all protective ground leads are properly connected
after having been disconnected or removed for repairs!

Mains power switch


Remove the Phillips head screw at the top of the operating panel (2.18).
Pull out the module with the control and display boards.
Remove the four connecting leads to the mains power switch (1.16).
Press the two clamping elements together on the sides of the mains switch, and pull out the
switch to the front.

Control and display boards


Remove the Phillips head screw at the top of the operating panel (2.18).
Pull out the module with the control and display boards.
Disconnect the cables, as required. Remove the four mounting screws at the rear of the module,
and take out the boards.

Power distribution and motor control board


Remove the four mounting screws at the side of the power distribution and motor control board
(1.13).
Take out the cover with the board and disconnect the cables, as required.
The board is fixed on six separating rollers.

Shaking drive motor


Remove the power distribution and motor control board.
Disconnect the motor leads.
The three mounting screws of the DC gear motor are underneath the speed control disk.
Remove the screw at the swivel head (2.32).
Loosen both srews of the speed control disk. Remove the holding bracket of the light barrier
and take out the speed control disk.
After unscrewing the three mounting screws, remove the DC gear motor (1.22).

14
SW-21C

PTC Sensors (AF = working sensor and SF = safety sensor)


Drain the bath. Remove the shaking carriage.
Remove the Phillips head screw at the top of the operating panel (2.18).
Pull out the module with the control and display boards.
Disconnect the PTC sensor leads and remove the plug.
Remove the four mounting screws at the side of the power distribution and motor control board
(1.13).
Take out the cover with the board.
Loosen nut (SW 10) on the PTC sensor (1.24), and turn it completely to the end of the threaded
section. Continue turning to loosen and remove the sensor, but disconnect the safety sensor from
the heater coil first (spring and clip 2.14).
When remounting the sensor, use a new copper washer, and treat the threads with Loctite or
any similar sealing compound.
Do not forget to connect the safety sensor to the heater coil (spring and clip 2.14).

F After exchanging the sensor, recalibrate the control and display


boards.

Heater coil unit


Drain the bath. Remove the shaking carriage.
Remove the mounting screws from the large bottom cover plate.
Remove the four mounting screws at the side of the power distribution and motor control board
(1.13).
Take out the cover with the board.
Disconnect the two heater leads (Hg1 and Hg2) from the power distribution and motor control
board.
Unscrew the two mounting nuts (SW 8) to remove the heater coil unit (1.28).
The same rubber seals may be used for the replacement unit.

15
Component disassembly

Level switch
Drain the bath. Remove the shaking carriage.
Remove the mounting screws from the large bottom cover plate.
Remove the four mounting screws at the side of the power distribution and motor control board
(1.13).
Take out the cover with the board.
Disconnect the leads of the level switch from the power distribution and motor control board
(M1 or M2) and the pump motor.
Unscrew the mounting nut (SW 19) to remove the level switch (1.23).
When remounting the level switch, use new copper washers (A 13x18x1.5, Cu).

Cooling coil unit


Drain the bath. Remove the shaking carriage.
Remove the four mounting screws from the cover plate on the rear side of the unit.
Unscrew the mounting nuts (SW 17) to remove the cooling coil unit (2.17).
When remounting the cooling coil unit, use new copper washers (A 12x15.5x1.5, Cu,
2 pcs. inside and 2 pcs. outside).

Pump motor
Drain the bath. Remove the shaking carriage.
Remove the four mounting screws at the side of the power distribution and motor control board
(1.13).
Take out the cover with the board.
Disconnect the pump motor leads.
Remove the tubing from the pump connectors.
The circulating pump unit is fixed to the bottom cover plate with a holding bracket and two
screws.
Push the tubing onto the pump connectors and fix with tube clamps.

16
SW-21C

6. Calibration procedure

Necessary equipment : 4-digit multimeter


calibration thermometer, 0 to 100 C

Turn the temperature selector dial (2) fully to the left so that the heater does not start to operate.
Turn the shaking frequency selector dial (8a) fully to the left so that the motor does not start to
operate.
Fill the bath with deionized water. Minimum filling level: 70 mm. Using ice cubes, establish a test
temperature of 0 C in the bath (as measured by the calibration thermometer).
NOTE: In case the filling level is below 70 mm, the integrated level switch acting as low liquid
level protection does not switch on the pump motor unit. Thus an optimum temperature
distribution in the bath is prevented.
Connect the mains power cable to a grounded power socket and switch on the unit.

Power board: +15 V calibration


Set P1 for a voltage of +15 V 10 mV between the measuring points 0 VA and +15V .

Control board:
a) Temperature sensor calibration -0 V = 0 C (iced water)
Selector switch (4) for Multi-Display in position "ACTUAL".
The LED (10) for actual temperature value illuminates.
Working sensor: Set P3 for a voltage of 0.00 V 5 mV between the measuring points 0 V and
MP6.
Safety sensor: Set P5 for a voltage of 0.00 V 5 mV between the measuring points 0 V and
MP7.

17
Calibration procedure

b) Temperature sensor calibration - Slope (water temperature: about 80 C )


Heat the bath to approx. 70 to 80 C and measure the temperature with the calibration
thermometer.
A slope of 10 mV/K is adjusted with regard to this measured temperature value.
Example:
The measured bath temperature is 75.4 C. For a slope of 10 mV/K, set the voltage to
75.4 x 10 mV = 754 mV = 0.754 V.
Working sensor: Set P2 for a voltage of 0.754 V 5 mV between the measuring points 0 V and
MP6.
NOTE: The calibration of the working sensor effects the bath temperature.
Take into account the temperature change when setting the voltage value. Have a look at the
calibration thermometer!
Safety sensor: Between the measuring points 0 V and MP7, set P4 for the same voltage as for
the working sensor.

Display board
a) Multi-Display - Display calibration
After setting the slope on the control board, calibrate the display.
With P1, set the display to the value measured with the reference thermometer. (Example: 75.4)
b) Setpoint calibration
Turn the temperature selector dial (2) fully clockwise.
Selector switch (4) for Multi-Display in position "SET".
The LED (9) for setpoint temperature value blinks.
With P4, set the display to 90.0.
c) Control calibration
(Selector switch (4) for Multi-Display in position "SET".)
Set the temperature selector dial (2) to 50.0.
Selector switch (4) for Multi-Display in position "ACTUAL".
Allow bath to cool down (if necessary, add cold water) to 50.0 C (as measured by the
calibration thermometer). With the selector switch (4) in position "SET" or "ACTUAL" the same
values must be displayed.

18
SW-21C

If this is not the case, correct the deviation with P1 on the control board.

Check the absolute accuracy: Heat the bath to 50 C. The max. deviation between calibration
thermometer and display should be 0.5 K. If necessary, repeat the calibration procedure.

d) Check the shaking frequency


Setting range: 40 ... 200
Remount the shaking carriage.
Selector switch for Multi-Display (4) in position "R.P.M.".
The LED (8b) for shaking frequency blinks.
Set the shaking frequency selector dial (8a) to 100. In case the display toggles, adjust the light
barrier.
Count the number of displacements of the shaking carriage for one minute (Example: 97).
With P3, set the display to the counted number (Example: 97).

e) Check the selected safety temperature (for example: at a bath temperature of 50.0 C)
Setting range: 20 ... 93 C

Selector switch for Multi-Display (4) in position " ".


The LED for the selected safety temperature (7b) blinks.
With the safety temperature adjustment screw (7a) set the Multi-Display to 49.5.
The unit signals an alarm.
The red control light "ALARM" (6) illuminates and the buzzer SG1 sounds. The alarm relay
REL1 effects a complete shutdown of the heater and pump.
With the safety temperature adjustment screw (7a) set the Multi-Display to the maximum value.
Cancel the alarm state by pressing the mains switch off and on.

19
Circuit and component mounting diagrams

7. Circuit and component mounting diagrams


Power distribution and motor control board, 230 V 7.501.5730
Power distribution and motor control board, 115 V 7.501.5740
Power distribution and motor control board
component mounting diagram 6.501.5730

Control board 7.503.5730


Control board component mounting diagram 6.503.5730

Display board 7.509.5731


Display board component mounting diagram 6.509.5731

Vocabulary used on circuit diagrams (in alphabetical order):


German English
A(rbeits )-Fhler Working sensor
A-Ist Actual working temperature
A-Soll Setpoint working temperature
(zur) Displayplatine (to) Display board
Drehz(ahl) Ist Actual r.p.m.
Drehz(ahl) Soll Selected r.p.m.
Druckwchter Level switch
Gabellichtschranke Light barrier
Heizung Heater
Hg-Puls Heater pulse
Motor AUS Motor OFF
(zur) Netzplatine (to) Power board
Pumpe Pump
(zur) Reglerplatine (to) Control board
S(icherheits )-Fhler Safety sensor
S(icherheits )-Soll Selected safety temperature
Schttelmotor Shaking motor
Temperatur Sollwert Setpoint temperature
U ref. Reference voltage

20