Chopin RHEO F4 Maintenance Manual
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Chopin RHEO F4 Maintenance Manual

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RHEO F4
Maintenance manual
MM-RHEOF4-EN ind. 1
09/2014
-
20, avenue Marcellin Berthelot - Z.I. du Val de Seine
92396 Villeneuve La Garenne cedex - France
www.chopin.fr
Tél. : 33 (0)1 41 47 50 88 - Fax. : 33 (0)1 47 92 28 27

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  • Page 1 RHEO F4 Maintenance manual MM-RHEOF4-EN ind. 1 09/2014 20, avenue Marcellin Berthelot - Z.I. du Val de Seine 92396 Villeneuve La Garenne cedex - France www.chopin.fr Tél. : 33 (0)1 41 47 50 88 - Fax. : 33 (0)1 47 92 28 27...
  • Page 3 The technical elements that constitute this manual (text and illustrations) are not contractual, their only target being to bring assistance for troubleshooting and repairing the Rheo F4. Use, duplication or disclosure of subject data, for any purpose other than relating to the servicing or repair of this equipment, is strictly prohibited without the written authorisation of CHOPIN Technologies.

  • Page 5: Table Of Contents

    Rheo F4 Table of contents Chapter 1 Operation & Maintenance: reminders & additional information ... . 7 Operating conditions ........9 Precautions linked to testing .
  • Page 6 Rheo F4 Maintenance manual MM-RHEOF4-EN ind. 1 - 09/2014...

  • Page 7: Chapter 1 Operation & Maintenance: Reminders & Additional Information

    Rheo F4 Chapter 1 OPERATION & MAINTENANCE: REMINDERS & ADDITIONAL INFORMATION Maintenance manual  MM-RHEOF4-EN ind. 1 - 09/2014...
  • Page 8 Rheo F4 Maintenance manual MM-RHEOF4-EN ind. 1 - 09/2014...

  • Page 9: Operating Conditions

    Operating conditions ■ Installation The RHEO F4 must be installed on a flat, clean and tidy bench. The device must not be installed close to a water source (taps). The device must not be exposed to sunlight or heat sources.

  • Page 10: Precautions Linked To Testing

    In particular, thoroughly clean the bowl rubber seal and the lid surface. ■ Between two tests When the Rheo F4 is not being used, in order to avoid condensa- tion and mould, do not tightly close the tank: leave the cover laid on the studs.

  • Page 11: Control And Maintenance

    Rheo F4 Control and ■ Additional menus maintenance In addition to those described in the Operating Manual, the Rheo- fermentometer incorporates other "screens" giving access to extra information and adjustments which may be useful while isolating a fault or performing particular controls.
  • Page 12 (antistatic floor, grounded wrist). For maximum efficiency of maintenance activities on the Rheo F4, especially when more than one device are run, it is recommended to carefully record all pieces of information relating to the device during its life time.

  • Page 13: Chapter 2 Troubleshooting

    Rheo F4 Chapter 2 TROUBLESHOOTING Maintenance manual  MM-RHEOF4-EN ind. 1 - 09/2014...
  • Page 14 Rheo F4 Maintenance manual MM-RHEOF4-EN ind. 1 - 09/2014...

  • Page 15: Method

    The aim of this chapter is, in case a fault appears, to discover the probable origin and to isolate the failed com- ponent or sub-assembly, if any; recovery actions from this situation are then detailed. For any inquiry to CHOPIN Technologies Service Department, please mention the serial no of the equipment. Method ■...

  • Page 16: Failure Modes

    Rheo F4 Failure modes Declared faults If the measurement seems abnormal, check on the synoptic screen that read values are not aberrant. Item Description Height sensor value Temperature sensor value Pressure sensor value HEIGHT FAULT Read height value is aberrant.
  • Page 17 Abnormal test results The recording curves hereunder show the typical effects of some internal failures occurring in the Rheo F4. For analysis of "normal" results, i.e on a Rheo in good working order, refer to the Operating Manual Rhéo F4.
  • Page 18 Rheo F4 CURVE TYPE 3 GAS RELEASE Presence of a fault Pressure values recorded in direct cycle are too low. CURVE TYPE 4 GAS RELEASE Presence of a fault Early curve separation. CURVE TYPE 5 GAS RELEASE Presence of a fault Pressure values recorded in indirect cycle fall to zero, while those in direct cycle are too high.
  • Page 19 Rheo F4 CURVE TYPE 6 GAS RELEASE Presence of a fault Pressure values recorded in direct and indirect cycles remain to zero. CURVE TYPE 7 GAS RELEASE Presence of a fault Pressure values recorded in indirect cycle remain to zero.

  • Page 20: Troubleshooting Instructions

    Rheo F4 CURVE TYPE 9 DOUGH DEVELOPMENT Presence of a fault No height measurement recorded. (Note: there is no fault message as for A-2, considering the meas- urement value not being "out of range") Other faults INSUFFICIENT HEATING The heating is insufficient if the set temperature of the protocol is never met, or if the time to reach it is abnormally long.
  • Page 21 Rheo F4 A-1. Height fault Height fault Check sensor connections. Move connectors while checking the display of height Connection or cable damaged? Replace the cable/repair Change the height sensor the connection (see op. 1- (see op. 1- 2 p.48) 3 p.49) Maintenance manual ...
  • Page 22 Rheo F4 A-2. Temperature fault Temperature fault Check that sensor is correctly connected Fault still present? Check supply and measure voltages (5V and 10mV/C) (see op. 6- 7 p.70) Supply voltage = 5V Measure voltage 10mV/C? (see op. 3- Check connection Replace CPU board 1 p.55)
  • Page 23 Rheo F4 A-3. Pressure fault Pressure fault Check the function of valves, particularly valve C Valve C remains closed? Replace the Re-calibrate electrovalve the sensor module (see op. 6- 3 p.64) (see op. 5- 1 p.59) Fault still present? Replace the...
  • Page 24 Rheo F4 A-4. Communication failure RHEO F4 No communication between PC and RHEO F4 Restart the RHEO F4 Reset the application Fault still present? Check the connection (test with another cable) between PC and CPU board. Replace cable if necessary.
  • Page 25 Rheo F4 B-1. Curve type 1 Curve type 1 Check the pressure sensor: - menu FUNCTIONS CONTROL - open electrovalves A and C (check on display that the opening is effective) - check by mean of the hand pump that any pressure variation is read...
  • Page 26 Rheo F4 Check tank outlet orifice and air filter ports (see op. 1- 3 p.49) Orifice obstructed? Clean concerned By mean of an air-leakage test element search for an substantial leakage (tank outlet level, or pressure (see op. 6- measurement circuit level) 4 p.66)
  • Page 27 Rheo F4 B-2. Curve type 2 Curve type 2 GAS RELEASE Check function of electrovalve A from menu FUNCTIONS CONTROL (listen if its electro-magnet switches properly) Electrovalve A defective? Perform a new test, Replace the and contact Chopin electrovalve module...
  • Page 28 Rheo F4 B-3. Curve type 3 Curve type 3 GAS RELEASE Check function of electrovalve B from menu FUNCTIONS CONTROL (listen if its electro-magnet switches properly) Electrovalve B defective? Perform a new test, Replace the and contact Chopin electrovalve module...
  • Page 29 Rheo F4 B-4. Curve type 4 Curve type 4 GAS RELEASE Clean out the soda lime cartridge (see Operating Manual) Perform a new test Problem cleared? Contact Chopin log_10 Maintenance manual  Chapter 2 Troubleshooting MM-RHEOF4-EN ind. 1 - 09/2014...
  • Page 30 Rheo F4 B-5. Curve type 5 Curve type 5 GAS RELEASE Check function of electrovalves B and B' from menu FUNCTIONS CONTROL (listen if its electro-magnet switches properly) Electrovalve B or B' defective ? Perform a new test, Replace the...
  • Page 31 Rheo F4 B-6. Curve type 6 GAS RELEASE Curve type 6 Dough development curve correct? Check the pressure sensor: - menu FUNCTIONS CONTROL - open electrovalves A and C (check on display that the opening is effective) - check by mean of the hand pump...
  • Page 32 Rheo F4 Check tank outlet orifice and air filter ports (see op. 1- 3 p.49) Orifice obstructed? Clean concerned By mean of an air-leakage test element search for an substantial leakage (tank outlet level, or pressure measurement circuit level) (see op. 6- 4 p.66)
  • Page 33 Rheo F4 B-7. Curve type 7 Curve type 7 GAS RELEASE By mean of an air-leakage test search for a substantial leakage in the indirect circuit (at soda lime cartridge level or electrovalves B and B') (see op. 6- 4 p.66)
  • Page 34 Rheo F4 B-8. Curve type 8 GAS RELEASE Curve type 8 Check function of electrovalve C from menu FUNCTIONS CONTROL (listen if its electro-magnet switches properly) Electrovalve C defective? Inspect the Replace the venting orifice electrovalve module log_14 (see op. 5- 1 p.59)
  • Page 35 (see op. 6- 1 p.62) Measurement correct? Perform a new test, and contact CHOPIN Replace height sensor Technologies if fault persists (see op. 1- 2 p.48) Fault still present ? Replace CPU board (see op.
  • Page 36 Rheo F4 Dough sample present? Replace the Perform a CPU board new test (see op. 3- 1 p.55) Problem cleared? Contact CHOPIN Technologies Maintenance manual Chapter 2 Troubleshooting MM-RHEOF4-EN ind. 1 - 09/2014...
  • Page 37 Rheo F4 C-1. Insufficient heating Insufficient heating Heating time > 1 hours Wait until temperature Control the heating temperature is stabilized on the display (see op. 3- Sign flashing 1 p.55) at the botton of the window? Remplace Check voltage on terminals...

  • Page 38: Interconnection Diagrams

    Rheo F4 Interconnection The two below diagrams may help to solve troubleshooting failures. diagrams 4.1 Principle diagram Temperature probe board Heating resistors Height sensor Safety thermostat Power supply Electrovalve board Main module switch Electrical interconnection Connection 230 Vac Electrovalves open - closed ❍...
  • Page 39 Rheo F4 4.2 Pneumatic cabling diagram (with cable length) Maintenance manual  Chapter 2 Troubleshooting MM-RHEOF4-EN ind. 1 - 09/2014...
  • Page 40 Rheo F4 Maintenance manual Chapter 2 Troubleshooting MM-RHEOF4-EN ind. 1 - 09/2014...

  • Page 41: Repair

    Rheo F4 Chapter 3 REPAIR Maintenance manual  MM-RHEOF4-EN ind. 1 - 09/2014...
  • Page 42 Rheo F4 Maintenance manual MM-RHEOF4-EN ind. 1 - 09/2014...

  • Page 43: Introduction

    Rheo F4 Chapter 3. Repair This chapter details all corrective maintenance operations, authorised by CHOPIN, that can be carried out on the Rheo F4 (some of these instructions are in particular called out from Chapter 2 "Troubleshooting"). Spare parts and sub-assemblies shall be selected from the illustrated parts lists of Chapter 4 "Spare...
  • Page 44 Rheo F4 1.2 List of instructions The table below lists all corrective maintenance operations that are detailed in the herein procedures. In addition, this list reminds for each procedure: ❏ particular ingredients to be used, ❏ needed specific tools, ❏ minimum required competence.
  • Page 45 Rheo F4 Instruction Ingredients Specific tools Competence Operation 3-2.Replacing the CPU-mounted fuse Power supply board Operation 4-1.Dismounting/mounting the power supply board Pneumatics elements Operation 5-1.Dismounting/mounting the electrovalve module Operation 5-2.Dismounting/mounting the air filter Adjustment and checks Operation 6-1.Displacement measurement Ruler TECH Operation 6-2.Temperature probe calibration...

  • Page 46: Instructions

    Rheo F4 Instructions See following pages Maintenance manual Chapter 3 Repair MM-RHEOF4-EN ind. 1 - 09/2014...
  • Page 47 (C). Remove the 4 attachment screws of the upper casing (D) (two on each side of RHEO F4). Remove the upper casing, taking care not to tear off the cables, and unscrew the earth cable located under the soda lime compartment (E).
  • Page 48 Rheo F4 1 Basic operations Sheet: 1 / 1 Operation 1-2 Dismounting/mounting the displacement sensor Consumables: Tools: Unplug the electrical connection from the upper part of sensor (A). Unscrew the sensor body from the plexiglass cover (B), and remove it (C).
  • Page 49 Rheo F4 1 Basic operations Sheet: 1 / 1 Operation 1-3 Electical and pneumatic interconnections Consumables: - Tube Cristal 4 x 7 - Voir Chapter 4 Tools: - Flat screwdriver ❏ Dismount the cover/sensor assembly and the upper casing (see 1-1).
  • Page 50 Disconnect the two terminals from the power switch module and the power supply board. Unplug the earth cable from the power supply board and CPU board, and from the RHEO F4 frame (A). Press the upper clip on the module so as to disengage it from the electronics support (B).
  • Page 51 Rheo F4 2 Tank Sheet: 1 / 1 Operation 2-1 Dismounting/mounting the tank Consumables: Tools: - Allen key Dismount the cover/sensor assembly and the upper casing (see op. 1-1). Unplug the tubes linking the tank to the electrovalve module (A). If the tubes cannot be extracted, cut them at nozzle level.
  • Page 52 Rheo F4 2 Tank Sheet: 1 /1 Operation 02-2 Replacing a heating resistor Consumables:  Compound grease used for high power heating resistors.  heat shrink sleeve - dia: 4.8 before shrinkage, Cable tie Tools: Thermogun, Allen key, pliers Dismount the tank (see Operation 2-1).
  • Page 53 Rheo F4 2 Tank Sheet: 1 / 1 Operation 2-3 Replacing the temperature probe Consumables: - Silicone heat conductive compound. Silicone bonding material, Rubson or equivalent.  Tools: - Allen key, pliers Dismount the tank (see Operation 2-1). Dismount the stainless steel casing by removing the clips and disconnecting the earthing cable.
  • Page 54 Rheo F4 2 Tank Sheet: 1 / 1 Operation 2-4 Replacing the safety thermostat Consumables: - Silicone heat conductive compound Tools: - Allen key Dismount the tank (see Operation 2-1). Dismount the stainless steel casing by removing the clips and disconnecting the earthing cable.
  • Page 55 Rheo F4 3 CPU board Sheet: 1 / 2 Operation 3-1 Dismounting/mounting the CPU board Consumables: - Tube Cristal 4 x 7, Cable tie Tools: - Cutting pliers, pliers, Allen Key, Cutter Dismounting the CPU board Dismount the cover/sensor assembly and the upper casing (see op.
  • Page 56 Re-plug all electrical and pneumatic connections on the CPU board (A). Remount the Rheo F4 upper casing, and mount the cover/sen- sor assembly on to the tank. If the CPU board is a new one, proceed with the re-calibration...
  • Page 57 Rheo F4 3 CPU board Sheet: 1 / 1 Operation 3-2 Replacing the CPU-mounted fuse Consumables: Tools: - Pliers It is recommended to first dismount the CPU board (see op. 3- Exchange the fuse located near the heating resistors connec- tor.
  • Page 58 Rheo F4 4 Power supply board Sheet: 1 / 1 Operation 4-1 Dismounting/mounting the power supply board Consumables: Tools: - Allen Key, Pliers Dismount the cover/sensor assembly and the upper casing (see op. 1-1). Unscrew the four attachment nuts of the power supply board (A).
  • Page 59 Rheo F4 5 Pneumatics elements Sheet: 1 / 2 Operation 5-1 Dismounting/mounting the electrovalve module Consumables: - Tube Cristal 4 x 7, Cable tie Tools: - Allen key, Cutter Dismounting the electrovalve module Dismount the cover/sensor assembly and the upper casing (see op.
  • Page 60 (F). Re-plug the module supply connector to the CPU board (A). Reconnect all tubes on the electrovalve module (B, C,D). Remount the Rheo F4 upper casing. Remount the cover/sensor assembly on to the tank Proceed with an air leakage test (see op.
  • Page 61 Rheo F4 5 Pneumatics elements Sheet: 1 / 2 Operation 5-2 Dismounting/mounting the air filter Consumables: - Cable tie Tools: - Cutting pliers, Cutter Dismount the cover/sensor assembly and the upper casing (see op. 1-1). It is recommended to first record the position of pneumatic connections.
  • Page 62 Rheo F4 6 Adjustment and checks Sheet: 1 / 1 Operation 6-1 Displacement measurement Consumables: Tools: Ruler Operations below are carried out with powered on device connected to computer. Measurement Go to [Tools] tab, menu [Maintenance] and enter the code 3213 to access to sub-menu.
  • Page 63 Route a long-spindle thermometer in the temperature control bracket provided with the device and place it in the hole at the bottom of the Rheo F4 tank (C). Go to [Tools] tab, menu [Maintenance] and enter the code 3213 to access to sub-menu.
  • Page 64 Connect a pressure source fitted with a valve and a "T nut" and inject 100mm to the manometer CHOPIN or pressure manome- ter. Check on the corresponding value of the manometer CHOPIN or pressure manometer, the difference shall not exceed ± 1 mm O....
  • Page 65 Rheo F4 replug the tube on the pressure sensor of the CPU board. Pressure source Valve Manometer CHOPIN CPU board RHEO F4 Maintenance manual  Chapter 3 Repair MM-RHEOF4-EN ind. 1 - 09/2014...
  • Page 66 Rheo F4 6 Adjustment and checks Sheet: 1 / 2 Operation 6-4 Air leakage test Consumables: Tools: Global checking Operations below are carried out with fitted and screwed cover, powered on device connected to computer. Go to [Tools] tab, menu [Maintenance] and enter the code 3213 (A) to access to sub-menu.
  • Page 67 Rheo F4 6 Adjustment and checks Sheet: 2 / 2 Operation 6-4 Air leakage test Consumables: Tools: Leakage isolation In order to better locate a leakage, the screen FUNCTIONS CON- TROL may be useful. It gives in particular the possibility to indepen- dently activate each electrovalve.
  • Page 68 Rheo F4 6 Adjustment and checks Sheet: 1 / 1 Operation 6-5 Checking power supply voltages Consumables: Tools: Voltmeter The opening of the Rheo requires to first switch power off and unplug the power cable. Open the Rheo. Check that all electrical connectors are plugged in.
  • Page 69 Rheo F4 6 Adjustment and checks Sheet: 1 / 1 Operation 6-6 Check of displacement sensor characteristics Consumables: Tools: Ohmmeter Operations below are carried out with powered on device connected to computer. Go to [Tools] tab, menu [Maintenance] and enter the code 3213 (A) to access to sub-menu.
  • Page 70 The opening of the Rheo requires to first switch power off and unplug the power cable. Open the Rheo F4. Plug in the mains cable, then switch on the Rheo F4. Presence of 230 Vac inside. By means of a voltmeter, measure voltages at temperature probe connector level while following sketch below....
  • Page 71 Rheo F4 6 Adjustment and checks Sheet: 1 / 1 Operation 6-8 Check of the heating circuit Consumables: Tools: - Ohmmeter The opening of the Rheo requires to first switch power off and unplug the power cable. Open the Rheo.
  • Page 72 Rheo F4 Maintenance manual Chapter 3 Repair MM-RHEOF4-EN ind. 1 - 09/2014...

  • Page 73: Chapter 4 Spare Parts

    Rheo F4 Chapter 4 SPARE PARTS Maintenance manual  MM-RHEOF4-EN ind. 1 - 09/2014...
  • Page 74 Rheo F4 Maintenance manual MM-RHEOF4-EN ind. 1 - 09/2014...

  • Page 75: Warnings

    It is a fact that, on one hand, repair procedures of chapter 3 do not cover other spare parts, and on the other hand CHOPIN will never provide other parts than those referenced in these lists.
  • Page 76 Rheo F4 figure 1 - Rheo F4 - General Maintenance manual Chapter 4 Spare parts MM-RHEOF4-EN ind. 1 - 09/2014...
  • Page 77 Displacement sensor assembly RHF-26C "T"-nuts RH176 Cable CPU - Displacement sensor F4 CB-177 Power cable AL 72 Cable Rheo F4 - PC CB157 Pressure pump RHF 37 Temperature control bracket Soda lime cartridge RHF4-4 O-ring seal for soda lime cartridge...
  • Page 78 Rheo F4 figure 2 - Pneumatic elements and mains switch Maintenance manual Chapter 4 Spare parts MM-RHEOF4-EN ind. 1 - 09/2014...
  • Page 79 RH-167 Stainless M5x10 hexagon socket round head screw Stainless 5 external teeth Washer Stainless M5X12 hexagon socket head cap screw Electrovalve module RF4-21 Tank assembly RHEO F4 RF4-1 Maintenance manual  Chapter 4 Spare parts MM-RHEOF4-EN ind. 1 - 09/2014...
  • Page 80 Rheo F4 figure 3 - Rheo F4 - Boards Maintenance manual Chapter 4 Spare parts MM-RHEOF4-EN ind. 1 - 09/2014...
  • Page 81 Rheo F4 Rheo F4 - Boards Part N. Item Description min. Note CHOPIN deliv. Stainless 3x8 hexagon socket head cap screw Power supply board SEN-150 CPU board RHEO F4 RF4-CPU Stainless M3x10 hexagon socket head cap screw CPU Board fuse Maintenance manual ...
  • Page 82 Rheo F4 figure 4 - Tank assembly Maintenance manual Chapter 4 Spare parts MM-RHEOF4-EN ind. 1 - 09/2014...
  • Page 83 Rheo F4 Tank assembly Part N. Item Description min. Note CHOPIN deliv. Heating resistor RHF-47 Bichromate steel 4x10 washer Zinged-plated steel M4x6 screw Zinged-plated steel dia 5 large washer Zinged-plated steel dia 5 large washer Stainless 5 toothed washer M5x10 stainless hexagon socket round...
  • Page 84 Rheo F4 Maintenance manual Chapter 4 Spare parts MM-RHEOF4-EN ind. 1 - 09/2014...

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