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Retsch ZM200 Repair Manual
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Retsch ZM200 Repair Manual

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© Retsch GmbH, 42781 Haan, Retsch-Allee 1-5, Germany
Version Q25.08.2015

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Summary of Contents for Retsch ZM200

  • Page 1 Repair Manual for Rotor Mills Ultra-Centrifugal Mill ZM200 © Retsch GmbH, 42781 Haan, Retsch-Allee 1-5, Germany Version Q25.08.2015...
  • Page 2 Copyright  Copyright by Retsch GmbH Retsch-Allee 1-5 D-42781 Haan Germany...
  • Page 3 Notes on the Repair Manual ........................5 General Points ........................... 5 Important instructions for all repair work .................... 5 Necessary documents ........................5 Tools ..............................5 Returned goods delivery note/declaration of safeness ..............6 Packaging, Transport and Set-Up ......................8 Disassembly, Assembly and Repair Instructions ................
  • Page 4 3.8.3 Description of the procedure ......................27 Replacing the Motor ......................... 29 3.9.1 Required tools: ..........................29 3.9.2 Required spare parts: ........................29 3.9.3 Description of the procedure ......................29 3.10 Software (Firmware) Update ......................31 3.10.1 Required tools: ......................... 31 3.10.2 Required spare parts: ......................
  • Page 5 For your own safety, we recommend that you have the necessary repairs done only by Retsch GmbH or an authorised agency (service technicians). If repairs not described in this manual are necessary, please consult your supplier...
  • Page 6 Hex key A/F 4 Needle-nose pliers 1.5 Returned goods delivery note/declaration of safeness If it is necessary to return a machine to Retsch, the returned goods delivery note and the declaration of safeness must be used. Such a form can be downloaded from www.retsch.com.
  • Page 7 (enclose safety data sheet):  I/we assure that the details in this declaration are correct and complete. I am/we are aware that RETSCH can refuse to accept particularly contaminated devices/accessories or devices/accessories that present inestimable health risks for RETSCH employers.
  • Page 8 Packaging, Transport and Set-Up 2 Packaging, Transport and Set-Up WARNING Serious personal injury Falling loads The appliance is very heavy and can therefore cause serious personal – injuries if it falls down. • Lifting above head height is not permissible! The packaging has been adapted to the mode of transport.
  • Page 9 Disassembly, Assembly and Repair Instructions 3 Disassembly, Assembly and Repair Instructions 3.1 Taking off the Housing 3.1.1 Required tools: Hexagonal socket wrench A/F 7 Hex key A/F 4 3.1.2 Required spare parts:: 22.153.0003 spare housing 22.153.0002 housing lid 05.009.0060 cover cap 3.1.3 Description of procedure If the housing lid was closed normally (without...
  • Page 10 Disassembly, Assembly and Repair Instructions To unlock the closure gear, insert the key As you push the key in, turn it in a clockwise and then push it in further with some degree direction as far as it will go. of force.
  • Page 11 Description of the procedure Switch on the device and open the lid. Put the Press the inside of the brass adjusting device out as labyrinth disc along with the O-ring and the cassette far as it will go. base onto the ZM200.
  • Page 12 Open the ZM200 and carefully take out the test To adjust the trunnion, first release the lock nut by device. . Use a calliper gauge to measure the...
  • Page 13 Disassembly, Assembly and Repair Instructions Repeat the adjusting procedure until the At the end, check if the lock nut is tight. measurement is between 29.40mm and 29.50mm.
  • Page 14 4 x 05.009.0060 cover cap 3.3.3 Description of the procedure Disconnect the ZM200 from the mains supply and Use an Allen key to loosen all 6 screws fastening the open the housing. Take all connectors off the control control PCB to the component carrier.
  • Page 15 It is important to use all 6 screws. Now connect all plug-in contacts. Use the enclosed Take care about the two bridges for the safety scan circuit diagram as an aid. . this is not required for the ZM200.
  • Page 16 Disassembly, Assembly and Repair Instructions Now connect all plug-in contacts. The interface function USB and colour display are not activatied yet. Speed sensor Display Colour display connection RS 232 DR100 Interlock Secure the interface connection RS485 into the Assemble the housing and check that the interface cabel channel it is no longer necessary.
  • Page 17 Disassembly, Assembly and Repair Instructions 3.4 Replacing the Frenic-Mini Frequency Converter 3.4.1 Required tools: Phillips screwdriver Ph1 Hexagonal socket wrench A/F 7 3.4.2 Required spare parts: 22.199.0002 spare frequency converter 3.4.3 Description of the procedure CAUTION: These instructions describe how to replace a defective frequency converter for ZM 200 Ultra Centrifugal Mills with change index I.
  • Page 18 Disassembly, Assembly and Repair Instructions Disconnect the frequency converter from the brake Place the new frequency converter on the base resistors, motor and power supply and take it out. plate and screw it in using the existing screw holes. Connect the connection cables in accordance with Put the interface card downwards onto the the terminal assignment described in the circuit frequency converter.
  • Page 19 Disassembly, Assembly and Repair Instructions Put some talcum powder onto the rubber seal, in particular on the vertical surface and assemble the machine again completely.
  • Page 20 Disassembly, Assembly and Repair Instructions 3.5 Replacing the Siei Frequency Converter with a Frenic-Mini FC 3.5.1 Required tools: Phillips screwdriver Ph1 Hexagonal socket wrench A/F 5.5 Hexagonal socket wrench A/F 7 Hex key A/F 2.5 Hex key A/F 5 Hex key A/F 4 3.5.2 Required spare parts: 02.1990008 Retrofit kit frequency converter...
  • Page 21 Disassembly, Assembly and Repair Instructions Now, fasten these components in the new rear wall. Now, replace the brake resistors with new ones. Please make sure the fan’s direction of air flow is correct. The direction arrow must point inwards. Now fasten the new rear wall onto the base plate. Remove the cable duct on the component carrier Put all the enclosed stickers on it.
  • Page 22 Disassembly, Assembly and Repair Instructions It is essential to pay attention to conduct and Remove the connector on the motor cable and lead position the ribbon cable for the lid lock correctly. the cable through the lower sleeve. Stick the short cable duct onto the rear wall. Run all cables into their correct positions.
  • Page 23 Disassembly, Assembly and Repair Instructions Attach the connection cables in accordance with Put the interface card downwards onto the the terminal assignment (see circuit diagram). frequency converter. Take special care not to damage the contacts! Put the interface cable onto the interface card. Put the other end of the interface cable into the control PCB.
  • Page 24 Disassembly, Assembly and Repair Instructions Put some talcum powder onto the rubber seal, in particular on the vertical surface and assemble the machine again completely. Check that the motor is rotating in the right direction and the interfaces are functioning properly.
  • Page 25 Disassembly, Assembly and Repair Instructions 3.6 Replacing the Display 3.6.1 Required tools: Hexagonal socket wrench A/F 7 3.6.2 Required spare parts: 02.569.0014 display unit old Siei frequency converter 02.569.0019 display unit new Frenic frequency converter 02.569.0019 display unit TFT until index “Q” display required GP2 board for TFT 3.6.3 Description of the procedure Disconnect the ZM 200 from the mains supply and...
  • Page 26 Disassembly, Assembly and Repair Instructions 3.7 Replacing the Fan 3.7.1 Required tools: Hexagonal socket wrench A/F 7 Hex key A/F 2.5 3.7.2 Required spare parts: 05.402.0002 fan 05.742.0017 filter mat 3.7.3 Description of the procedure Disconnect the ZM 200 from the mains supply and Pull the fan connector off the control PCB.
  • Page 27 Disassembly, Assembly and Repair Instructions 3.8 Replacing the Motor-Driven Lid Lock 3.8.1 Required tools: Hex key A/F 2.5 Needle-nose pliers 3.8.2 Required spare parts: 22.878.0015 motorised lock 3.8.3 Description of the procedure Disconnect the ZM 200 from the mains supply Pull the motorised lock connector off the control and open the housing.
  • Page 28 Disassembly, Assembly and Repair Instructions Put the protective conductor onto the protective conductor contact and guide the ribbon cable Insert the lock connector into the control through the opening intended for it. PCB. Note, the pin nose must engage into the hole intended for it.
  • Page 29 Hex key A/F 4 Flat-blade screwdriver Ph1 3.9.2 Required spare parts: 05.009.0060 cover cap 02.441.0399 spare motor ZM200 3.9.3 Description of the procedure Disconnect the ZM 200 from the mains supply Disconnect the motor cable from the frequency and open the housing.
  • Page 30 Disassembly, Assembly and Repair Instructions Move the motor out downwards through the Now take the new replacement motor and insert the component carrier. enclosed fan filter. It is important to screw in only to finger tightness! Mount the replacement motor in the component Now attach all connections to the control, while carrier.
  • Page 31 Disassembly, Assembly and Repair Instructions 3.10 Software (Firmware) Update Pos : 3.30 /00015 R eper atur- und Montageanl eitung en/00005 R eparatur anl eitungen/05010 R ep Kapitels ammlung Cr yoMill/00010 Demontag e, M ontag e und R epar atur en/10010 R ep Modul Softwar e U pdate Cr yoMill @ 1\mod_1244193202729_6.doc @ 10817 @ 3333 3.10.1 Required tools: Laptop or PC...
  • Page 32 Disassembly, Assembly and Repair Instructions Press the “Upload Now“ button. The selected After a successful update the program appears when firmware will be transmitted now. confirmed with “OK”. Please switch the machine off now, remove the interface cable and start the machine again.
  • Page 33 Disassembly, Assembly and Repair Instructions 3.11 Error Messages PROBLEM IN THE LID LOCK’S SAFETY CIRCUIT 1. Possible cause if the lid is open: One of the two Hall sensors for detecting the trunnion is defective or the trunnion magnets have got dirty or dropped out. SERVICE REQUIRED! Remedy: Replace the motorised lid lock or clean or...
  • Page 34 Disassembly, Assembly and Repair Instructions SERVICE INTERVAL Possible cause: HAS EXPIRED The service interval time has expired. PLEASE SERVICE DEVICE CONTINUE WITH STOP Remedy: Do the maintenance work! Call up the service interval in the menu and reset! Possible cause: Hall sensor PCB defective ROTOR DOES NOT ROTATE...
  • Page 35 Drawings 4 Drawings Legenden für Zeichnungen Keys to drawings Dichtung mit Klappe verkleben Stick sealing to flap Unterbaugruppe Gehäuse Housing sub-assembly Option Trafo: Nicht verwenden bei 230 V Transformer option: do not use at 230 V. Variante 20.823.0001 Variant 20.823.0001 Unterbaugruppe Bauteilträger Component carrier sub-assembly Unterbaugruppe Frequenzumrichter...
  • Page 36 Drawings 4.1 Views of the Device...
  • Page 37 Drawings...
  • Page 38 Drawings...
  • Page 39 Drawings...
  • Page 40 Drawings...
  • Page 41 Drawings...
  • Page 42 Drawings...
  • Page 43 Drawings...
  • Page 44 Drawings...
  • Page 45 Drawings 4.2 Circuit diagram for the device...
  • Page 46 Drawings...
  • Page 47 The main board GP2 05.748.0179 was replaced with the GP2 board TFT 05.748.0193  Display TFT 02.569.0019 – display required GP2 board for TFT  Now free access to the main fuses on the backside of the ZM200  Firmware update GP2 board version V01.06 ...
  • Page 48 Index 6 Index Adjusting device ..........12 Necessary documents ......... 5 New display ............25 Notes on the repair manual ......... 5 Changes ............. 47 Changing the frequency converter ..... 20 Circuit diagram for the device ......45 Old display ............25 Connection cable ..........