YSI 2300 STAT Plus YSI 2700 SELECT YSI 2710

Service Manual

www.ysilifesciences.com

Table of Contents
1. Description ......................................................................................................... 1-1 2. Analyzer Mechanical Parts and Procedures ........................................................... 2-1 2.1 Recommended Replacement Parts ................................................................................................. 2-1 2.2 Exploded Views with Parts Lists.................................................................................................... 2-2 2.3 Service Procedures ....................................................................................................................... 2-12 2.3.1 Sipper Mechanism Removal/Installation (See Figure 2.1) ........................................... 2-12 2.3.2 Timing Belt Replacement (See Figure 2.6) .................................................................. 2-12 2.3.3 Optical Sensor Replacement (See Figure 2.6) .............................................................. 2-13 2.3.4 Stir Motor Assembly Removal/Installation (See Figure 2.6)........................................ 2-13 2.3.5 Sipper Board Removal/Installation (See Figure 2.6) .................................................... 2-13 2.3.6 Printer Removal-Installation (See Figure 2.2) .............................................................. 2-14 2.3.7 Keypad and Display Removal/Installation (See Figure 2.2)......................................... 2-14 2.3.8 Sipper Pump Removal/Installation (See Figure 2.5) .................................................... 2-14 2.3.9 Peristaltic Pump Motor Removal/Installation (See Figure 2.1 and Figure 2.8) ............ 2-14 2.3.10 Sipper Alignment Procedures ..................................................................................... 2-15 2.3.11 Door Alignment.......................................................................................................... 2-16 2.3.12 High Voltage Shield Removal/Installation (See Figure 2.8) ...................................... 2-16 3. Analyzer Electronic System .................................................................................. 3-1 3.1 Circuit Descriptions........................................................................................................................ 3-1 3.1.1 Power Supply.................................................................................................................. 3-1 3.1.2 Analog Circuits............................................................................................................... 3-1 3.1.3 Microprocessor ............................................................................................................... 3-2 3.1.4 Stepper Motor Drivers .................................................................................................... 3-2 3.1.5 Bottle Level Sensing....................................................................................................... 3-2 3.1.6 Printer ............................................................................................................................. 3-2 3.1.7 Serial Interface................................................................................................................ 3-3 3.1.8 Interconnect and Sipper Boards...................................................................................... 3-3 3.1.9 Display and Keypad........................................................................................................ 3-3 3.2 PC Boards and Schematics ............................................................................................................. 3-5 4. Service and Repair Tips........................................................................................ 4-1

5. Turntable Mechanical Parts and Procedures .......................................................... 5-1 5.1 Recommended Replacement Parts ................................................................................................. 5-1 5.2 Exploded Views with Parts Lists.................................................................................................... 5-1 5.3 Service Procedures ......................................................................................................................... 5-8 5.3.1 Sample Wheel Removal/Installation .............................................................................. 5-8 5.3.2 Turntable Drive Hub Removal/Installation .................................................................... 5-8 5.3.3 Bottom Panel Assembly Removal/Installation ............................................................... 5-8 5.3.4 Timing Belt Replacement ............................................................................................... 5-8 5.3.5 Optical Encoder Assembly Removal .............................................................................. 5-9 5.3.6 Optical Encoder Assembly Installation .......................................................................... 5-9 5.3.7 Drive Housing Assembly Removal/Installation ............................................................. 5-9 6. Turntable Electronic System................................................................................. 6-1 6.1 Circuit Descriptions........................................................................................................................ 6-1 6.2 Turntable Main PC Board............................................................................................................... 6-1 6.3 Daughter Board Operation.............................................................................................................. 6-1 6.4 PC Boards and Schematics ............................................................................................................. 6-3

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1. Description
The 2300 Stat PLUS and 2700 SELECT Service Manual is written for service personnel. It contains the major parts and assemblies for the 2300 STAT PLUS and 2700 SELECT analyzers. The manual includes exploded view illustrations, part numbers, disassembly/assembly instructions and other relevant service and repair information. The manual was developed assuming that the repair person has the appropriate users manual nearby. The part numbers for the users manuals are as follows: 2300 STAT Plus Users Manual (printed version) 2700 SELECT Users Manual (printed version) 2300 STAT Plus / 2700 SELECT Users Manual (CD version) 062861 062521 577000

1-1

2. Analyzer Mechanical Parts and Procedures

2.1 Recommended Replacement Parts
Board Assy, Interconnect Board Assy, Main Diode, MR751 Diode, LM385Z Diode, IN4003 Fuse, PCB Mount, 1A Fuse, PCB Mount, 2A Fuse Holder, PCB Mount Regulator, LM323K Regulator, 7905 Regulator, 7805 Transistor, MJE701 Board Assy, Sipper Bottle Assy, Cal Bottle Assy, Supply Bottle Assy, Waste Cable Assy, Needle Ground Display Assy Keypad Assy Magnetic Stir Bar Motor Assy, Peristaltic Pump Sipper Needle Assy Printer Assy Preventive Maintenance Kit Probe Assy, Enzyme Pump Assy, Sipper Pump Head, Peristaltic Sipper Assy Cable, Sipper, w/clamp Motor Assy, Stir Belt, Timing, Sipper Motor Assy, Sipper Drive Optical Sensor Motor Assy, Vertical Drive Temp Probe Assy 527053 026071 060090 066116 062427 062428 062617 061762 062181 030319 061775 527050 110011 110010 110009 110052 110051 023220 062255 110014 062502 527013 2788 110923 062506 061895 110926 110925 110005 061959 110055 027071 110054 062265

2-1

2.2 Exploded Views with Parts Lists

Figure 2.1

Front Components

2-2

Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

YSI Part No. 062287 023029 062357 062506 062279 062235 062502 110926 061895 062236 062321 062319 062320 110010 110009 110011 062247 110050 023008 062241 062292 062418

Qty 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1

Description Bezel, Support Housing Paper Cover Assy Pump Assy, Sipper Panel Assy, Side Bulkhead Sipper Needle Assy Sipper Mechanism Pump Head, Peristaltic Baseplate Cable Assy, Cal, White Cable Assy, Waste, Red Cable Assy, Supply, Black Bottle Assy, Supply (061971 bottle only) Bottle Assy, Waste (061982 bottle only) Bottle Assy, Cal Bracket Assy, Cup Carrier Carrier Assy, Cup Spring, Cup Carrier Motor Shield Latch, Door (not shown) Spacer, Door Latch (not shown)

2-3

Figure 2.2

Operator Panel Assembly Ref 12 1 2 3 4 5 6 7 8 YSI Part No. 110048 110051 023220 062414 527013 023001 070910 061671 062421 Qty 1 1 1 1 1 1 1 1 1 Description Keypad/Display Assy (includes Ref 1 and 2) Display Assy Keypad/Backplate Clamp, Tear Bar Printer Assy Bezel Tear Bar Print Head Cable, Print Head

2-4

Figure 2.3

Stir Motor Assembly Ref 1 YSI Part No. 110005 Qty 1 Description Stir Motor Assembly

2-5

Figure 2.4

Sample Chamber Assembly Ref 1 2 3 4 5 6 7 8 9 10 YSI Part No. 110923 061944 110049 062255 062265 062174 110056 062305 077803 062543 Qty 2 1 1 1 1 1 1 1 2 1 Description Probe Assy, Enzyme (includes Ref 9) Electrode Housing, Black Chamber, Sample (includes Ref 2 and 6) Stir Bar, Magnetic (not shown) Probe Assy, Temperature Electrode Housing, White Chamber Assy, Waste O-Ring, Chamber Probe Sleeve O-ring, Temperature Probe (not shown)

2-6

Figure 2.5

Sipper Pump Assembly Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 YSI Part No. 110057 061946 061950 038237 062259 062522 027070 062503 062498 062499 062512 062500 060476 Qty 1 1 1 1 1 2 1 1 1 1 1 1 1 Description Motor Assy, Sipper Pump Frame, Sipper Pump Drive Hub Dowel Pin O-Ring O-Ring Optical Sensor Body, Sipper Pump, with Tubes Spacer Cap, Screw Housing Housing, Sipper Pump Plunger, Sipper Pump Mount, Adhesive

2-7

Figure 2.6

Sipper Mechanism

2-8

Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

YSI Part No. 062171 061967 062362 027071 110005 061897 061076 023045 023046 061928 061927 110054 061954 110055 061990 110053 061924 061923 061959 061961 061930 061932 527050 062176 061926 023047 023051 061956 061994 061969

Qty 1 2 1 1 1 2 1 1 1 1 4 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 2

Description Guide Assy, Sipper Needle Bearing, Flanged Spring, Cal Well Ground Optical Sensor Motor Assy, Magnetic Stirrer Bearing Pulley, Timing Belt Bracket, Idler Roller, Idler Plate, Motor Standoff, Alum. Motor Assy, Vertical Drive U-Joint Motor Assy, Horizontal Drive Bracket, Sensor Photosensor Assy Flag, Rotary Sensor Pulley, Modified Belt, Timing Washer, Thrust Block, Spacer Plate, Main Frame Board Assy, Sipper Shroud Assy Flag, Sensor Post, Roller Retainer Screw, Shoulder, Idler Screw, Sipper Needle Mounting Thumbnut, Sample Chamber (not shown) Stud, Sample Chamber (not shown)

2-9

Figure 2.7

PC Boards and Cables Ref 1 2 3 3 3 3 4 5 6 7 8 9 10 11 12 13 14 15 15 16 16 YSI Part No. 062341 062366 110230 110231 110232 110233 023235 062293 110925 023000 527055 062553 062552 062594 062593 023011 023002 060005 062497 060004 062511 Qty 1 1 1 1 1 1 1 3 1 1 1 1 1 2 2 1 1 1 1 1 1 Description Cable Assy, Display Cable Assy, Printer Board Assy, Main, 2300S Board Assy, Main, 2300D Board Assy, Main, 2700S Board Assy, Main, 2700D Door, Rear Cable Assy, 10 In. Cable Assy, Sipper, 24 In. w/clamp Door, Front Board Assy, Turntable Daughter Cable, Auxiliary Connector Cable, Main/Daughter Board Spacer, Daughter Board Standoff, Daughter Board Plate, Side Hinge, Door, Front Logo, 2300 STAT Plus Logo, 2700 SELECT Window, Door, 2300 STAT Plus Window, Door, 2700 SELECT
2-10

Figure 2.8

Rear Components Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 YSI Part No. 110014 527053 062417 062291 062315 062224 062388 061694 061679 062597 062553 000802 028110UL 028111 Qty 2 1 1 1 1 1 2 1 1 1 1 4 1 1 Description Motor Assy, Peristaltic Pump Board Assy, Interconnect Shield, High Voltage Transformer, Signal A41-25-10 Cable Assy, RS232 Switch Assy, Reset Jack Socket Transformer A41-80-24 Hinge, Continuous, Rear Door Filter, Power Line Cable Assy, Auxiliary Foot, Rubber Cord, AC, 110V (not shown) Cord, AC, 220V (not shown)

2-11

2.3 Service Procedures

2.3.1 Sipper Mechanism Removal/Installation (See Figure 2.1) 1. Unplug instrument. 2. Remove tubing connected to waste tube and to bottom of cal well. 3. Remove three screws which secure motor shield. 4. Pull motor shield forward and remove. 5. Remove probe assemblies (including temperature electrode) from the side(s) and back of sample chamber. NOTE: When working with single channel units, the blank plug does not need to be removed. 6. Disconnect plugs at locations J-6, J-7, J-8, J-9, J-12, and J-13 on interconnect board, releasing sipper mechanism cables. 7. Loosen (DO NOT REMOVE) two 5/16 mounting nuts located between upper and lower plates of mechanism. 8. Slide mechanism to the left approximately 3/8" and pull forward while feeding wires through hole in case. 9. Repair, or replace entire sipper mechanism. 10. Reverse steps 18 to reinstall sipper mechanism. NOTE: Figure 3.1 shows component connections to interface board. 2.3.2 Timing Belt Replacement (See Figure 2.6) 1. Remove sipper mechanism as described in "Sipper Mechanism Removal". 2. Loosen idler pulley to relieve belt tension. 3. Remove 4 screws which secure block spacers to lower plate. 4. Manually turn U-joint to raise needle to its upper limit. NOTE: Maintain needle at its upper limit throughout the rest of this procedure. If needle is left in chamber, it could be damaged if mechanism is moved horizontally. 5. Loosen top 2 hex screws on U-joint, releasing acme screw. 6. Carefully remove lower plate. 7. Remove 2 screws which secure sensor mounting block to upper plate. 8. Remove sensor mounting block. 9. Use a firm pull to remove spur gear (hex screws, used only on old instruments, do not need to be loosened). 10. Replace worn belt with a new one 11. Reverse steps 29 to reassemble sipper mechanism. 12. Check and adjust alignment of sensor flag (Horizontal Alignment, steps 2 - 8). 13. Check and, if necessary, adjust sipper needle alignment before resuming instrument operation.

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2.3.3 Optical Sensor Replacement (See Figure 2.6) 1. Remove sipper mechanism as described in "Sipper Mechanism Removal". 2. Remove 4 screws (2 on top, 2 on bottom) that secure optical sensor mounting block to upper and lower plates of sipper mechanism. 3. Slide mounting block from between upper and lower plates. 4. Remove 1 screw securing sensor to mounting block. 5. Remove optical sensor. 6. Reverse preceding steps with new sensor to reassemble instrument. 7. Realign needle after reassembly. Confirm correct needle alignment before resuming instrument operation. 2.3.4 Stir Motor Assembly Removal/Installation (See Figure 2.6) 1. Remove motor shield as described in "Sipper Mechanism Removal", steps 14. 2. Remove two screws which secure stir motor assembly to top plate of sipper mechanism. 3. Disconnect stir motor assembly cable connector at interconnect board (J7). 4. Pull stir motor assembly downward and remove. 5. Replace stir motor assembly. 6. Reassemble by reversing steps 35. 7. Power instrument, and operate stir motor to check alignment. If operation is noisy, loosen two screws holding motor assembly to top plate, shift motor assembly position, and retighten screws. Continue to step 8 when motor operates without excessive noise. 8. Reinstall motor shield to complete reassembly. 2.3.5 Sipper Board Removal/Installation (See Figure 2.6) 1. Make sure sipper needle is above sample chamber. 2. Unplug instrument and remove motor shield as described in "Sipper Mechanism Removal" Steps 14. 3. Disconnect two cable connectors on sipper board. 4. Remove sipper board mounting screw; lift and remove sipper board assembly. 5. Remove sipper board from shroud and replace. 6. Re-install shroud/board assembly and cables (Reverse operations of steps 3 and 4). 7. Turn spur gear to put needle in manual (sample) position. This is necessary in order to view sensor flag/sensor alignment in the next step. 8. Manually turn U-joint to raise needle to maximum height, making sure sensor flag travels through optical sensor on sipper board. If necessary, adjust sensor flag so that the flag is centered in optical sensor (Vertical Alignment, steps 24). 9. Reinstall motor shield and power instrument.
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10. Confirm correct sipper needle alignment; adjust if necessary. 2.3.6 Printer Removal-Installation (See Figure 2.2) 1. Unplug instrument. 2. Remove printer paper. (Cut paper between supply roll and printer slot, then pull remaining paper from top of printer.) 3. Unplug cable connectors J-15 and J-16 on interconnect board and J-9 on main board. 4. Remove two screws directly above supply and waste bottles which secure bezel and operator panel assembly to shelf, and pull bezel assembly from instrument. (See Figure 2.1). 5. Remove 4 screws which mount printer assembly to bezel. Note position of ground wire, if installed, for reassembly. 6. Service or replace printer assembly. 7. Reverse preceding steps to reassemble instrument. 2.3.7 Keypad and Display Removal/Installation (See Figure 2.2) 1. Remove printer as described in "Printer Removal", steps 15. 2. Remove 4 nuts which secure Keypad/Display Assembly to bezel. 3. Remove 4 screws securing display to backplate of keypad. 4. VERY carefully pry around display to remove it from the keypad adhesive. Do NOT bend or twist the display! 5. Replace display and/or keypad. 6. Reverse above steps to reassemble. 2.3.8 Sipper Pump Removal/Installation (See Figure 2.5) NOTE: Seal replacement does not require pump removal. 1. Unplug instrument. 2. Unplug sensor and motor wire connectors J-3 and J-5 on interconnect board. 3. Remove tubing from sipper pump fittings. 4. Remove 2 screws (one each; directly above and below sipper pump head) which secure pump to case. NOTE: Support sipper pump motor in rear of instrument while removing screws. 5. Pull pump head through mounting panel opening, and remove pump assembly from rear of instrument. NOTE: Be careful not to damage pump head fittings. 6. Service or replace sipper pump. 7. Reverse steps 15 to reassemble. NOTE: Tubing from sipper tube should be attached to fitting nearest front of pump. 2.3.9 Peristaltic Pump Motor Removal/Installation (See Figure 2.1 and Figure 2.8) 1. Unplug instrument.
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2. Remove 2 screws on front of pump head and pull pump head off. NOTE: Tubing does not need to be removed. 3. Remove 2 nuts that hold motor to case in back of instrument. Remove motor. 4. Inspect black rubber washers that go between wall and motor. Washers that are broken, cracked, or brittle must be replaced. 5. Install new motor, leaving nuts slightly loose. NOTE: When installing new motor, confirm that black rubber washers are in place between motor and wall. PERMANENT MOTOR FAILURE MAY RESULT IF RUBBER WASHERS ARE NOT PRESENT. 6. Reinstall spacer (if previously installed) and pump head, leaving screws loose. 7. Power-up instrument. 8. Exercise motor in diagnostic mode to allow self centering of pump. 9. Tighten pump head screws and pump motor nuts while motor is running. If binding occurs, loosen screws and nuts, and recenter. 2.3.10 Sipper Alignment Procedures The sipper mechanism is built with photosensors to detect vertical and horizontal movement. For proper operation, the mechanical components of the sipper mechanism must be correctly aligned with these photosensors and each other. Refer to Figure 2.6 to identify and locate components when performing the following procedures. Vertical Alignment 1. Place needle in manual (sample) position and at maximum height. (See Sipper Board Removal/Installation, steps 1,2,7 and 8). 2. Loosen the sensor flag mounting screw. 3. Adjust flag so it passes through center of slot in photosensor (located on sipper board). 4. Tighten sensor flag mounting screw. 5. Reinstall motor shield and repower instrument. 6. Confirm correct sipper needle alignment; adjust if necessary. Horizontal Alignment 1. Remove sipper mechanism as described in "Sipper Mechanism Removal". 2. Raise needle to its upper limit by manually turning U-joint. NOTE: Maintain needle at its upper limit throughout the rest of this procedure. If needle is left in chamber, it could be damaged if mechanism is moved horizontally. 3. Locate and loosen two set screws that secure sprocket to main shaft. 4. Turn sipper carrier to "Home" position (Tip of needle is over sample chamber.). Confirm correct position by placing a pin (A spare Allen wrench will work.) through alignment holes in the main frame plate and the base of the sipper carrier. 5. Rotate sprocket until set screws are oriented facing the left side and front of sipper mechanism.
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6. Place Allen wrench in left facing set screw and turn sprocket until wrench contacts front of left hand spacer block (Figure 2.6, Item 21). 7. Tighten both set screws, then remove pin from alignment holes in sipper carrier and main frame plate. 8. Reinstall aligned sipper mechanism 9. Check needle alignment; adjust if necessary. 2.3.11 Door Alignment Align the front door by adjusting hinge on right hand side of instrument. The catch (vertical positioning) can also be adjusted by loosening the two nuts on catch, located on inner left hand side of cabinet. Catch tension is also adjustable via two screws on top/bottom of catch. 2.3.12 High Voltage Shield Removal/Installation (See Figure 2.8) 1. Unplug instrument. 2. Unplug three cable connectors at positions J-1, J-12, and J-14 on interconnect board. 3. Lay cables over main board assembly. 4. Remove 2 screws which secure shield to case. 5. Carefully lift and move shield towards rear of instrument, being careful not to pinch any wires. 6. Perform service as needed in area exposed by shield removal. 7. Reverse steps 15 to reinstall shield. NOTE: Feed wires carefully through slots at each end of shield. Wires must not be pinched between shield and instrument housing (case).

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2-17

3. Analyzer Electronic System

This section describes the YSI 2300 Stat PLUS and 2700 SELECT electronic circuits. The circuit descriptions are followed by board layouts and schematics.

3.1 Circuit Descriptions

3.1.1 Power Supply Mains power is selectable to either 115 or 230 volts alternating current at the power switch assembly in the back of the instrument. When set to 115 volts, each transformer's primary windings are connected in parallel. When 230 volt operation is selected, the primary windings of each transformer are connected in series. The secondaries of both transformers are connected to the main circuit board through connector J15. The secondary of the main transformer is connected to a full wave center tapped rectifier, D13 and D14, and capacitive filter, C64 and C65, to provide the unregulated DC power at about 17 volts. U33 reduces and regulates this supply to five volts for use by the digital circuitry, and U34 reduces and regulates this supply to five volts for use by the analog circuitry. The unregulated power is also distributed through fuses F1 through F6 to the motor driver circuits. The secondary of the second transformer is connected to a full wave bridge rectifier, D15 through D18, and capacitive filter C58, to provide the unregulated DC power for the negative supply. U35 reduces and regulates this power to provide the negative five volts for the analog circuitry. An LED will be lit whenever the digital five volt supply is powered. 3.1.2 Analog Circuits The analog circuitry polarizes the probes and amplifies the nanoampere current signals to an appropriate voltage for conversion to a digital number. U30 and its associated circuitry is a differential dual channel front end amplifier for the enzyme probes. Each front end amplifier is a mirror image of the other up to the signal multiplexer, U29. The black chamber amplifier uses sections B and C of U30, and the white chamber amplifier uses sections A and D. For discussion the amplifier for the black chamber will be described. Section C senses the potential of the reference electrode of the probe in the black chamber and generates an output voltage seven hundred millivolts greater then the reference electrode to use as the probe polarizing voltage. Section B of U30 drives the working electrode with the polarizing voltage and also converts the probe current to a voltage with a gain of five millivolts per nanoampere. Chamber temperature is sensed by the RTD connected to J4. The RTD in combination with R65 forms a half bridge circuit whose output increases with increasing temperature. Under software control of signals MUXA and MUXB, U29 directs the signals from either chamber amplifier, the RTD half bridge, or signal common to the
3-1

programmable gain differential amplifier. U28 sections C and D, U27, and resistors R72 through R78 form a programmable gain differential amplifier. The output from the differential amplifier is fed into the input of a dual slope integrating analog to digital converter, U32. A 3.5 volt reference for the analog to digital converter is derived from a bandgap reference, D32, and amplifier U28A. Voltage converter U31 generates the negative supply voltage for U29 and U30 from the battery when power is off. Switching from the regulated analog power supply to the battery backup supply is provided for by diodes D26 through D29. 3.1.3 Microprocessor The controller architecture uses an 8-bit NSC800 microprocessor (U14). The system clock is derived from an 8 MHz oscillator controlled by X1. An octal latch (U9) separates the addresses from the data for use by the memory. The program code is stored in a 64K byte EPROM (U11), and program variables are stored in static RAM (U12). The memory is divided by a memory decoder section in the 22V10 PAL (U6) that generates the chip select signals for the ROM and RAM. A 68HC68T1 type real time clock, (U13) keeps time of day, controls power to the battery backup circuits and generates a power up reset signal. The power up reset signal and reset button signal are combined in U6 to get reset signal for the CPU. The I/O device selects are generated by U5. 3.1.4 Stepper Motor Drivers Each winding of the sipper arm stepper motors is connected to a 3717 type motor driver (U21-U24). Motor current is regulated by a current chopping technic to a value programmable by the I1 and I0 input pins connected to port A of U26, and current direction is controlled by the PH pin connected to the upper half of port B. The lower half of port B controls the sipper pump with a ULN2803 motor driver, U25. Pumps are controlled from port C with transistor drivers Q4 through Q6. 3.1.5 Bottle Level Sensing Timer zero in U20 is used to generate a 16 kilohertz square wave clock that is filtered by R23 and C42 to remove the higher frequency harmonics. This clock is routed to one of the four level sensing amplifiers on the Interconnect and sipper arm boards by U18. The return signal from the appropriate level sensing amplifier is also selected by U18 and is sent to rectifier detector circuit, U17C, D6, D7, R6 and R7. The detector signal is filtered by R4 and C30 to remove high frequencies before it goes to a comparator, U16. The comparator output will stay at logic high until the detector signal is greater then the voltage from the digital to analog converter, U19 and U17A. The output of the digital to analog converter is also used to adjust the speed of the chamber stirring with U17B, Q1 and Q2. 3.1.6 Printer Printer data is transferred through port A of U4, and printer control signals are connected to port C. The remainder of U4's pins are used to control the analog gain, multiplexing and analog to digital circuits.

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3.1.7 Serial Interface The serial interface is implemented with an NSC858 UART, U1. The RS-232 level signals are generated by U2 and U3. 3.1.8 Interconnect and Sipper Boards All four capacitive level sensing preamplifiers work by the same principle. An excitation signal is fed through an R-C network to the noninverting input of the amplifier. The level sensing probe is capacitively coupled to the center of the RC network. When the probe capacitance to ground is high enough, the excitation signal is shunted away from the amplifier and its output drops. 3.1.9 Display and Keypad The display and keypad are controlled from U15. Port A is used for the 8-bit data to and from the alphanumeric liquid crystal display module. Part of port B is used for the display interface control lines, and the rest of port B is used for the column scan lines in the keypad matrix. The rows of the keypad matrix are connected to port C. Timer zero of U15 drives a charge pump circuit, U7, to generate the display contrast voltage.

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3-4

3.2 PC Boards and Schematics

These schematics and drawings are representative only. Your instrument may be different.

Figure 3.1

2300/2700 Block Diagram

3-5

Figure 3.2

Main PC Board Layout

3-6

Figure 3.3

Main PC Board, Sheet 2

3-7

Figure 3.4

Main PC Board, Sheet 3

3-8

Figure 3.5

Main PC Board, Sheet 4

3-9

Figure 3.6

Main PC Board, Sheet 5

3-10

Figure 3.7

Main PC Board, Sheet 6

3-11

3-12

Figure 3.8

Main PC Board, Sheet 7

3-13

Figure 3.9

Main PC Board, Sheet 8

3-14

Figure 3.10

Interconnect PC Board

3-15

Figure 3.11

Interconnect PC Board, Sheet 1

3-16

Figure 3.12

Interconnect PC Board, Sheet 2

3-17

Figure 3.13

Sipper PC Board

3-18

Figure 3.14

Sipper PC Board, Schematic

3-19

Figure 3.15

Keypad Pinout

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4. Service and Repair Tips

Error: "Sipper/Needle Interference" This error message is usually caused by an intermittent break (or open) in the sipper cable. The sipper cable (YSI #110925) is the blue ribbon cable which is connected to the main sipper mechanism. This cable is easy to replace, however, we recommend the replacement be done by a qualified service technician. Other causes of this error include a faulty sipper board assembly or possibly a fluid leak. Also, verify the unit (2300 or 2700) is connected to a properly grounded AC outlet. Error: "Sipper Pump/Motor Failure or Sipper Homing Error" If the fuse holder (rear case of instrument) is installed backwards, sipper pump/motor failure will occur. Verify the installation of the fuse holder using the pictorial in your instruction manual. If the fuse holder is installed correctly and the preventative maintenance was recently done on the sipper pump, try the following procedure: Unplug the 2300/2700 and remove the screws on the back panel. Lower the back panel and look closely at the BACK of the sipper pump. On the back of the pump there is a black "hub" which, when turning, moves the sipper pump plunger in and out. On the hub, there is a thin disc which goes through a U-shaped optosensor. Rotate the hub manually and visually make sure the disc is not contacting the optosensor. This will cause the error! If the disc is rubbing the optosensor, loosen the hex screw on the hub. Re-position the hub so that the disc is "centered" in the optosensor. Re-tighten hex screw. If the problem still persists, try placing a thin film of grease on the back of the white sipper pump base and on the threads of the sipper pump plunger. If the sipper pump appears "dead" and does not make any noise, check the circuit board mounted fuse labeled F6 on the main PCB. Error: "Vertical Motor Failure/Jam" If the main fuse holder (back side of instrument) is installed backwards, it will cause the vertical motor errors. The index mark can be difficult to see. If at one point the fuse holder is removed, it is very easy to install it backwards. The "220 - 240V" stamped mark should be closest to the AC line cord for 110-120 volt operation. When installed backwards, the instrument will power the logic circuits and run some of the other motors, even though the voltage is low. The sipper cable (blue ribbon cable attached to sipper board) is intermittent, this also can cause vertical motor errors. This cable is easily replaced, however, we recommend this be done by a qualified service technician. Another cause for this error is the positioning of the sipper needle ground cable. This cable must be installed such that its crimp connector is parallel with the sipper needle (flange). If it is not, the crimp may come into contact with its own connector while attempting to reach its "home" position.
4-1

Error: "Final Baseline" Among the most common causes of this error are enzyme membranes, high sample concentrations and buffer pump tubing problems. If a new membrane was recently installed, it may take several hours before complete baseline stabilization has occurred. If the membrane has not been recently replaced, do this first unless there is an obvious leak on the system. Secondly, replace the buffer tubing if necessary. This tubing should be replaced every 2 to 6 months, depending on the calibration frequency and the number of samples that are presented to the unit. If the tubing has "flattened" out, the buffer pump will not be able to pump the correct amount of buffer through the system to flush the sample chamber. Error: "Bottle Errors" All reagent and waste bottles must be in the instrument bottle compartment or bottle errors will likely occur. The level sensing depends on capacitive sensing to "ground". If the errors still occurs, cleaned the bottles and the bottle compartment area where the bottom of the bottles rest. Placing a paper towel underneath the bottles can also cause this error. Finally, verify the instrument is plugged into a GROUNDED AC outlet. Error: "Sample Chamber Overflow" This error is limited to early versions of the Model 2300 STAT. It is normally caused by either an intermittent sipper cable (Blue ribbon cable connected to sipper board) or an improperly adjusted sipper needle. When performing the sipper needle alignment in the SERVICE mode, make sure the tip of the sipper is 1/16th of an inch above the cone in the sample chamber. This should be adjusted to 1/16" during the FINE alignment of the sipper needle. The sipper cable (blue ribbon cable attached to sipper board) can be replaced easily, however, we recommend this procedure be done by a qualified service technician.

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5. Turntable Mechanical Parts and Procedures

5.1 Recommended Replacement Parts
Belt, Timing Board Assembly, 2710 Stepper Driver Cable, Interconnect Diode, Light Emitting Encoder Indexing Fixture Motor Assembly Gear/Pulley Assembly Spring, Garter Switch Assembly, Reset Wheel, Sample Wrench, Hex 061959 527056 062160 062557 062554 062548 062560 062571 061076 062569 062602 062611 062600

5.2 Exploded Views with Parts Lists

The exploded views and parts lists on the next several pages will help you identify individual components, if you need to order parts from YSI.

5-1

Figure 5.1

2710 Turntable Assembly

5-2

Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14

YSI Part No. 062592 062563 062611 062567 062578 062560 062569 062557 062603 061642 001280 001790 002670 062600

Qty 1 1 1 1 1 1 2 1 1 2 4 4 4 1

Description Housing Assembly, Bottom Housing Assembly, Drive Wheel, Sample Housing, Top Drive Hub Indexing Fixture Spring, Garter Cable, Interconnect Cable Assembly, Encoder Screw, Set, Hex Socket Nut, Hex, Lock Screw, Mach., 6-32 Washer, Lock, #6 Wrench, Hex, T-Handle

Figure 5.2

2710 Turntable Accessories

5-3

Figure 5.3

2710 Bottom Housing Assembly

5-4

Ref 1 2 3 4 5 6 7 8 9 10 11

YSI Part No. 062568 062602 061758 527056 062554 061732 062440 000802 001280 001710 002670

Qty 1 1 1 1 1 1 2 4 4 4 4

Description Housing, Bottom Switch Assembly, Reset Guard, Switch PC Board Assembly Light Emitting Diode (LED) Connector, Plug, 3 Conductor Terminal, Crimp Foot, Rubber Nut, Hex, Lock Screw, Machine, 6-32 Washer, Lock, #6

5-5

Figure 5.4

2710 Drive Housing Assembly

5-6

Ref 1 2 3 4 5 8 9 10 11 12 13 14 15 16 17 18 19 20

YSI Part No. 062564 062572 061076 061959 061923 062573 062565 061673 062575 062548 001710 062571 002680 002670 062585 001036 006755 002690

Qty 1 1 1 1 1 1 1 4 1 1 2 1 4 2 1 2 2 2

Description Housing, Top Drive Bearing, Flanged Gear/Pulley Assembly Belt, Timing Pulley, Modified Bearing, Flanged Plate, Drive Screw, Machine, 8-32 Shaft, Main Drive Encoder, Optical Screw, Machine, 6-32 Motor Assembly, Drive Washer, Lock, #8 Washer, Lock, #6 Collar, Shaft Screw, Set, 6-32 Screw, Machine, 2-56 Washer, Lock, #2

5-7

5.3 Service Procedures

5.3.1 Sample Wheel Removal/Installation 1. Grasp the wheel firmly with both hands and raise it straight up. Rock gently side to side, if necessary. 2. To reinstall, slide the Sample Wheel down over the Drive Hub until the wheel stops. 3. Gently rotate the wheel until it drops into the indexing slot of the Drive Hub. 5.3.2 Turntable Drive Hub Removal/Installation 1. Remove Sample Wheel as described in "Sample Wheel Removal". 2. Loosen the two set screws in the Drive Hub, releasing it from the Main Drive Shaft. 3. Slide the Drive Hub up and off the Main Drive Shaft. 4. Reverse steps 2 and 3 to install the Turntable Drive Hub. 5. Check alignment of the Turntable "home position" (See Section 5.2, Sample Wheel/Drive Hub Alignment). Adjust, if necessary. 5.3.3 Bottom Panel Assembly Removal/Installation 1. Unplug the instrument. 2. Remove the Drive Hub as described in "Turntable Drive Hub Removal". 3. Remove the 4 screws and the 4 lock washers that secure the Bottom Panel Assembly to the Top Housing. 4. Carefully remove the Top Housing, disconnecting the Encoder Cable from location J-7 and the Motor Cable from location J-1 on the PC Board. 5. Reverse steps 2 through 4 to reinstall the Bottom Panel Assembly. 5.3.4 Timing Belt Replacement 1. Remove Bottom Panel Assembly as described in "Bottom Panel Assembly Removal". 2. Remove the 4 nuts that secure the Drive Housing Assembly to the Top Housing. 3. Slide the Drive Housing Assembly off the mounting studs in the Top Housing. 4. Remove the 4 screws that secure the Drive Plate to the Top Drive Housing. 5. Carefully remove the Drive Plate. 6. Use a firm pull to remove the Spur Gear (hex screws do not need to be loosened). 7. Replace worn belt with a new one. 8. Reverse steps 2 through 7 to reassemble the mechanism.

5-8

5.3.5 Optical Encoder Assembly Removal 1. Remove Bottom Panel Assembly as described in "Bottom Panel Assembly Removal". 2. Using a flat blade screwdriver, rotate the center slot of the Encoder Cap counterclockwise until the dot on the cap is aligned with the single dot on the Encoder case. DO NOT ROTATE THE ENCODER CAP COUNTERCLOCKWISE PAST THE SINGLE DOT POSITION. 3. Insert a .035" hex wrench into the body of the Encoder. 4. While maintaining a slight pressure on the hex wrench, rotate the Spur Gear until the hex wrench seats in the Encoder Wheel Hub set screw. 5. Loosen the setscrew holding the Encoder Wheel Hub to the Main Drive Shaft. 6. Carefully snap the Encoder body off the Encoder Baseplate. 7. Carefully slide the Encoder body off the Main Drive Shaft. 8. Remove the 2 screws and the two lock washers that secure the Encoder Baseplate to the Drive Plate. 9. Slide the Encoder Baseplate off the Main Drive Shaft. 5.3.6 Optical Encoder Assembly Installation 1. Remount the Encoder Baseplate onto the Drive Plate and tighten the screws. Note, an alignment tool slipped over the Main Drive Shift can be used to better position the baseplate. 2. Slide the Encoder body onto the Main Drive Shaft. 3. Push the hex wrench into the Encoder body, seating it in the Encoder Wheel Hub set screw. 4. Apply a downward force on the end of the hex wrench. 5. Tighten the set screw while continuing to apply a downward force on the hex wrench. 6. Remove the hex wrench by pulling it straight out of the Encoder body. 7. Snap the Encoder body onto the Baseplate, locking all 4 snaps. 8. Using a flat blade screwdriver, rotate the center slot of the Encoder cap clockwise until the dot on the cap is aligned with the 2 dots on the Encoder case. 9. Replace the Bottom Panel Assembly. 5.3.7 Drive Housing Assembly Removal/Installation 1. Remove Bottom Panel Assembly as described in "Bottom Panel Assembly Removal". 2. Remove the 4 nuts that secure the Drive Housing Assembly to the Top Housing. 3. Carefully remove the Drive Housing Assembly from the studs in the Top Housing Assembly. 4. Reverse steps 1 through 2 to reinstall the Drive Housing Assembly.
5-9

5-10

6. Turntable Electronic System

6.1 Circuit Descriptions
The 2710 Turntable electronic system consists of two electrical printed circuit (PC) boards. One board is located inside the 2300/2700 Analyzer. This board is referred to as the "Daughter Board" of the 2300/2700 Main PC Board. The second board is located inside the 2710 Turntable and is referred to as the Main PC Board (of the 2710). Refer to Figure 6.1, Schematic of 2710 Main PC Board and to Figure 6.2 2300/2700 Daughter Board Location for additional information.

6.2 Turntable Main PC Board

The 2710 Turntable is powered by the shielded Interconnect Cable from the 2300/2700. Approximately 16.5 VDC at 1 ampere maximum is provided through fuse F2 on the 2300/2700 Main PC Board, through the Daughter Board and Interconnect Cable, and then into the 2710 Main PC Board. This voltage is then used to drive the turntable motor, and is regulated by VR1 to provide +5 VDC for logic power. All functions such as motor operation, positioning and communication are handled by the microcontroller. Data between the 2300/2700 and the 2710 are transmitted in serial format. An optical encoder is used to sense the position of the turntable sample wheel. These data are then interpreted by the microcontroller and sent to the 2300/2700.

6.3 Daughter Board Operation

The Daughter Board is a microcontroller based PC board that is used to handle the communications and translation between the 2300/2700 and the 2710 Turntable. The microcontroller, Motorola 68HC705, performs the operations of serial to parallel conversion and handles the handshaking and timing functions. This is done by making use of the ROM inside the 68HC705 and the flexibility of the programmable serial and parallel ports. Power and data are provided to the Daughter Board from the 2300/2700 via the ribbon cable connected at J-10 on the 2300/2700 Main PC Board and J-20 on the Daughter Board. Data are sent out to the Turntable Main PC Board via J-21 on the Daughter Board, which is connected to the 2300/2700 Auxiliary Port connector. A 15 conductor shielded cable carries the signals from the 2300/2700 to the 2710 Main PC Board.

6-1

Figure 6.1

2300/2700 Daughter Board Location

6-2

6.4 PC Boards and Schematics

Figure 6.2

2710 Main PC Board Layout

Figure 6.3

2300/2700 Daughter Board Layout

6-3

6-4

Figure 6.4

2710 Main PC Board Schematic

6-5

Figure 6.5

2300/2700 Daughter Board Schematic

6-6

1725 Brannum Lane Yellow Springs, Ohio 45387 USA 937 767-7241 800 765-4974 Fax 937 767-9353 Support@ysi.com www.ysilifesciences.com
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062863 A62863CPreliminary 2007-09