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ELTRA THERMOSTEP Service Manual
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ELTRA THERMOSTEP Service Manual

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 2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep
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Summary of Contents for ELTRA THERMOSTEP

  • Page 1  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 1...
  • Page 2 NOTE : This Service Manual serves as a support for service operations at Thermostep analyser of the company ELTRA. For further questions and support please contact the service technicans of the manufacturer. In this Service Manual, no information from the Operation Manual is repeated, however it is provided as established.
  • Page 3 Change of internal blower Change of cylinder of internal blower Change of balance Change of thermocouple 3.10 Change of motor 3.11 Change of power supply  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 3...
  • Page 4 Removal of upper heating element 3.17 Install of upper heating element 4. Miscellaneous Diagram of order numbers Diagram of wiring Diagram of gasflow List of Abbreviations/Figures  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 4...
  • Page 5 1. Starting up Please note that first start up of Thermostep-analyser has been done already before delivery of the instrument. The following described operations are not necessary to be done before the first analysis. By reason that a lot of service operations needs a new start up for the according component and for a better understanding of the working instructions the start up is described here detailed.
  • Page 6 6 x 2,0 mm screws (respectivly 3 screws at the left or rather at the right border of the metal sheet) and 2 x 2,5 mm screws in front of the internal blower (see Fig. 1.3).  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 6...
  • Page 7 Vibrations of the pedestal would disturb or prolong the weighing during analysis, because the balance would need longer time for stabilization. Same method is essential for lidcarousel.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 7...
  • Page 8 Mark the lower border of the detection area, as well. Site the sensor nearly at the middle of the detection area and fix the screw again.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 8...
  • Page 9 Follow the instructions of the measuring instrument. Installation of PC The PC is needed for the controlling of the Thermostep-analyser and for coordination of the analysis. For installation of the PC look at the Operation Manual: Start up. Programming of Balance, Adjustment of glass chimney The balance resides inside the TGA (Display: LHS;...
  • Page 10 24 V: supply voltage of the board (not measurable) 18 V: supply voltage of the balance 12 V: supply voltage of the board  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 10...
  • Page 11 To adjust the gas pressure extract the pressure controller and turn it until the required pressure is reached.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 11...

  • Page 12: Internal Blower

    Configuration). The closing speed should be fast enough to avoid collision with the cover. WARNING: The internal blower start automatically after lifting up! RISK OF INJURY!!!  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 12...
  • Page 13 Plese note that the scew has a wide surface area. A collision between screw and sensor has to be avoided at any time! The distance and the vertical position of homesensor is adjustable.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 13...
  • Page 14 A complete rotation should take place to be sure that every sprocket is able to pass the sensor without touching.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 14...
  • Page 15 If correct siting of the crucibles is not possible by using a calibration value between 600 and 1000 it is necessary to adjust the carusseladaptor.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 15...
  • Page 16 The cylinder at the RHS has two sensors, that control the status of the lid, whereas at the cylinder at the LHS two chokes control the speed of the movement.)  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 16...
  • Page 17 Regulate the speed via the chokes at the cylinder. The upper choke regulates the closing speed and the lower choke regulates the opening speed (see Fig. 1.12  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 17...
  • Page 18 Required tools: Screwdriver The external blower is necessary for cooling of Thermostep during analysis and for several of emerging flue gases. The exhaust air tube can be assembled at the backside (see Fig. 1.13) or at the interior of the analyser.
  • Page 19 Plug the dimmer at the socket at the backside of the analyser (see Fig. 1.13). The external blower starts automatically when it is connected to the dimmer and the Thermostep is switched on. Via dimmer you have the opportunity to adapt the power of the external blower. Optimal setting is approximately half dimmer power.
  • Page 20 After starting software a TGA initialisation test checks functionality of the analyser. For progress through this test Thermostep has to be switched on (position 1 or 2). The test checks the single fuctions one after another and interrupts when an error occurs. Depending at which function the test is interrupted it maybe necessary to open the analyser manually (see Operation manual: Form –...
  • Page 21 Check that analyser is switched on and cable connection between Balance and PC (serial port: COM2)! The acces to balance cable is at the LHS.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 21...
  • Page 22 RHS. Taring of balance is indicated by an accustic signal and 0.0000 at the display. Zu d.) Error message: “No communications! Please check cable, port settings and instrument.”  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 22...
  • Page 23 If test is interrupted at this point, check if the sensors a positioned correctly (see 1.2). After finishing initialization test sucessfully the cover of the analyser is opened automatically. No rotation of caroussel Error message: “Can't reach needed position!”  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 23...
  • Page 24 At d.) If it is not possible to solve the problem with a.)-c.) it is possible that the motor is defective. At this case it is probably necessary to replace the motor (see ). Please contact 3.10 manufacturer.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 24...
  • Page 25 (see )! Try to correct this by changing the 1.15 speed of movement via the chokes before replacing the cylinder (see  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 25...
  • Page 26  Replace the plastic hats at the switches and fasten the metal block again. Balance unstable Error message: “Balance is unstable, can’t tare!” An unstability of the balance can be caused by:  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 26...
  • Page 27 At a.) To minimize environmental influences site the Thermostep at a vibration-free, to supply-air protected place. To minimize the influence of air movements keep the lower side panels closed and use the function “...
  • Page 28 Stop analysis for this and open the cover, after cooling down, manually (see Operation Manual: Form – Controller). (Warning: Do not open the Thermostep while the furnace is hot! There is an increased risk of injury by hot pieces inside the furnace!!!) Check if crucibles are sited properly at the balance pedestal and/or if there are dislocations at the caroussels during lifitng up/down that stop a proper siting of the crucibles.
  • Page 29 At c.) In rare cases the gas pressure switch can be defective and needs to be replaced (see 2.2e No communication between PC, Analyser and/or Balance  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 29...
  • Page 30 600°C and stays at this position. A complete opening of the cover at 650°C kann be caused by: a.) to minor adjustment of the corresponding valve b.) a defective valve  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 30...
  • Page 31 At a.) Check the feeding gas pipe and the tube-connectors ath the 2. valve at the valveblock (LHS). At b.) Check the funtionality of the 2. valve at the valveblock and replace it if necessary (see  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 31...
  • Page 32 Check the temperature-course during analysis and note the shown and the determined temperature data at the single stages. Alternatively the instrument can be heated to the selected setpoint manually to measure the temperature externally.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 32...
  • Page 33 Please remember to use instrument only for external temperature determination without upper right side panel! Change of a valve at the manifold Required tools: 4 mm Allenkey 8 mm Allenkey open-ended wrench screwdriver  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 33...
  • Page 34 Listen for sounds that indicates a gas leckage and switch the valve via the button manually. Fig. 3.2.2: LHS – Manual check of valve functionality  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 34...
  • Page 35 The power supply of the valve is fixed by a screw (transparent header). Unfasten this screw (underside of the valve). Fig. 3.2.4: LHS – Unfasten the power supply of the valve  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 35...
  • Page 36 5 mm allen key screw driver The instrument possesses two caroussel cylinder, one to lift up/down the crucible caroussel and one for the lid caroussel.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 36...
  • Page 37 Remove the sensors from the cylinder by loosen in the 2,5 mm allen screw until you can remove of the sensor out of its fitting. b.) Remove the fitting.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 37...
  • Page 38 Unfasten the 5,5 mm hexagonal screw at the upper left edge of the board and hinge it down carefully. Fig. 3.5.1: RHS – Unfasten of the board to hinge it out  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 38...
  • Page 39 3 mm allen key a.) Lift the internal blower out of its well manually and put it on the lower metal sheet at the furnace.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 39...
  • Page 40 Fig. 3.6.2: FI – Power supply of internal blower c.) Connect cables of the new blower with power supply. d.) Remove cover of the removed blower.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 40...
  • Page 41 Fig. 3.7.1: LHS/RHS – Unfasten of front metal plate b.) Hinge out the front metal plate to get free access to the cylinder of the internal blower.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 41...
  • Page 42 Unplug instrument from electrical supply and disconnect the compressed air supply. Prop up lid using a section of heavy duty cardboard tube under the LHS pneumatic ram arm.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 42...
  • Page 43 Lift out balance pedestal and ceramic tube from the balance. Fig. 3.8.2: FI – Lift out balance pedestal Unscrew manifold on the LHS and hinge it out of the instrument carefully.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 43...
  • Page 44 On the RHS remove the 5.5mm nut which secures the TGA 1.2 pcb and hinge the board down to improve access to the balance (see Fig. 1.6). Disconnect the balance purge tube (No.27) from the side of the balance  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 44...
  • Page 45 Remove completely 2 x 4mm allen screws and 2 x aluminum disc from the front and rear of the balance base plate. Fig. 3.8.6: LHS/RHS – Loosen the balance shield  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 45...
  • Page 46 If installing a new balance fit it to the base plate. The balance communications settings are as follows: Reset Stable 9600 Baud Rate Auto Sense Stability  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 46...
  • Page 47 Fig. 3.9.1: TS – Unscrew top of cover b.) The thermocouple connects to the socket mounted at the rear inside the lid. Disconnect the cable from the plug.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 47...
  • Page 48 Fig. 3.9.3: TS – Disconnecting cable from the plug d.) Remove upper right side panel. e.) Unfasten the 4 x 3 mm allen screws and remove the isolation metal plate behind.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 48...
  • Page 49 Fig. 3.9.5: TS – Unscrewing fitting of Thermocouple cable g.) Remove the thermocouple out off the ceramic device.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 49...
  • Page 50 On the RHS unscrew the 2 x 4mm allen screws securing the purge valve module to gain better access to the motor. Fig. 3.10.1: RHS – Unscrewing purge valve module  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 50...
  • Page 51 Fig. 3.10.3: RHS – Unscrewing drive wheel from the shaft Undo the 4 x 2.5mm allen screws holding the motor and gearbox to the motor mount.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 51...

  • Page 52: General Information

    Lower Furnace Procedure. General Information Carousel Motor Drive Gearbox The Thermostep motor gearbox has a 40:1 ratio. The Thermostep carousel rotates in a clockwise direction and has 1600 steps between each crucible position. 3.11 Change of Power supply Required tools:...
  • Page 53 Lift off carousels and lift out centre shaft used to lift the lids. Remove 6 x 2 mm and 2 x 2,5 mm csk allen screws securing the stainless steel (s/s) furnace surround (see Fig. 1.3).  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 53...
  • Page 54 Check the carousel is now aligned with the slot on the RHS of any one of the support pins. This will be the home position and  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 54...
  • Page 55 General Information Thermostep Furnace Information Each element in the heater of the Thermostep (two in the upper furnace and one in the lower furnace) has an impedance of 39 ohms. All the three elements (two in the upper furnace, one in the lower furnace) are connected in parallel which gives a total impedance of 13 ohms.
  • Page 56 Fig. 3.16.2: BS - Removing back cover attaching screws f.) On the RHS slide out the Thermocouple from the furnace (see Fig. 3.9.6 – Page 50).  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 56...
  • Page 57 Fig. 3.16.3: TS – Removing bolts attaching the cover frame Fig. 3.16.4: TS - Lid lifted out of frame supported at the rear  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 57...
  • Page 58 Fig. 3.16.6: Loosing the steel strap around upper heating element m.) Loosen the 2 x 2.5mm allen screws securing each of the front three positioning supports and slide them forward to free the furnace.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 58...
  • Page 59 The ceramic tubes should not protrude more than 20mm inside the furnace wall. Once in position they should be fixed each side of the furnace with ceramic cement.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 59...
  • Page 60 Check the alignment with the lower furnace by slowly raising and lowering the lid by hand. There should not be any interference. g.) Reverse the above procedure from section 12 to complete the installation.  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 60...
  • Page 61 G a s fl o w A ir Ga s Po w e r In le t 60235 78010 72020 72010 Fig. 4.1: View from the front  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 61...
  • Page 62 26068 Fig. 4.2: LHS – lower side panel with notch for exhausting air tube  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 62...
  • Page 63 Fig. 4.3: Back side – with connected exhausting air tube and external blower  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 63...
  • Page 64 Fig. 4.4 : Cross-section – Side view  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 64...
  • Page 65 2xMutter M4 DIN 934 A2 2xScheibe M4 DIN 9021 A2 2xZahnscheibe M4 DIN 6798 A2 2xMutter M4 DIN 934 A2 Fig. 4.5: Top view – upper heating element  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 65...
  • Page 66 F R O N T S E i T E 2xZylinerschraube mit Innenschskant M5x12 DIN 912 A2 2xZahnscheibe Fig. 4.6: Top view – lower heating element  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 66...
  • Page 67 Innensechskant M5x20 DIN 912 A2 M5x20 DIN 912 A2 2xZahncheibe M5 2xZahncheibe M5 DIN 6798 A2 DIN 6798 A2 Fig. 4.7: Cross-section – Top view  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 67...
  • Page 68 Fig. 4.8: Inside view to front metal plate  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 68...
  • Page 69 Fig. 4.9: Overview – Caroussel adaptor  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 69...
  • Page 70 26025 60525 60236 60233 4xZylinderschraube mit Innensechskant 26243 M5x14 DIN 912 A2 60552 60240 60522 26319 26242 60631 60552 60234 26024 Fig. 4.10: LHS -Manifold  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 70...
  • Page 71 Fig. 4.11: Cross-section – Balance  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 71...
  • Page 72 60519 71001 jumper Platine 60540 B o h r u n g ø 1 2 Fig. 4.12: Purging of balance  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 72...
  • Page 73 26165 26260 FRONTSEITE – Fig. 4.13: Overview Cover-Cylinder  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 73...
  • Page 74 2 . 5 m m ² 9 4 F 8 3 8 A(in und zurück); F A1; C1; D1 26346 Abb. 4.14: Diagram of Wiring  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 74...
  • Page 75 4.3 Diagram of Gasflow Fig. 4.15: Diagram of Gasflow  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 75...
  • Page 76 Page 37: Fig. 3.3.1: Cylinder of Caroussel Page 38: Fig. 3.5.1: RHS – Unfasten the mainboard Page 39: Fig. 3.5.2: RHS – Plugs at the mainboard  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 76...
  • Page 77 Fig. 4.11: Cross-section – Balance Page 72: Fig. 4.12: Purging of balance Page 73: Fig. 4.13: Overview – Cover-Cylinder Page 74: Fig. 4.14: Diagram of Wiring  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 77...
  • Page 78 Page 75: Fig. 4.15: Diagram of Gasflow  2009 by ELTRA GmbH Germany – July 2009 – Service Manual Thermostep Page 78...