SERVICE MANUAL - Keison Products
Contents
1. bede 1 os04 1 muoi Transistor 1 mao Transistor LM324N F301 Um Zeoemik europlug 1959 imei Heatsink for wa tp ditsocker Transistor mounting kit Rte ejeje Pp eR 12 50 04 Motherboar d RADI SFR25 1008 C401 2200uF 50V elect 2 1 PCB Fuseholder PEB Fuseholder cover O L402 Thermaltrip 2amp 1 401 403 SPCOIOARelay Relaysocket see 3 rRLa04 405 PCO 1 sG t6 way TOC pug s 16 way 0 di header 966 S Wayheader Jz sy sWahede 9919 Woher 3 Sk 2Wayheader TP401 M0 10 Way test socket 1 sez 32 Way power socket i SK13 32 Way europlug E 0 SK15 32 Way reversed 1 europlug P C B 26593 issue 1 50 05 Fascia p c b Kebon P RODUC T Thank you for reading this data sheet For pricing or for further information please contact us at our UK Office using the details below UK Office Keison Products P O Box 2124 Chelmsford Essex CM1 3UP England Tel 44 0 1245 600560 Fax 44 0 1245 808399 Email sales keison co uk Please note Product designs and specifications are subject to change without notice The user is responsible for determining the suitability of this product2. are the same fit the new sensor following the guidelines in the next section The peristaltic pump does not work correctly Check the pumps power supply Check the pump drive motor The air blower does not start Check the power to the blower motor If power present change the motor If power is not present check the wiring to the motor starting at the blower on switch The air blower makes an excessive noise when running or its speed varies Either the fan or the motor bearing is dry or damaged Replace the fan motor assembly The air heater does not work when turned on in conjunction with the blower Check the power to the heater If power present change the heater refer to section 3 4 If power is not present check the wiring to the heater The heater cuts out before the set temperature has been reached Check the over temperature thermostat The needle on the de blocking device does not move when switched on Check the air supply to the deblocker Strip down and clean the de blocking device The compressor does not run when turned on Check the power to the compressor If power present change the compressor refer to section 3 5 If power is not present check the wiring to the compressor The air pressure supplied by the compressor is insufficient Check the operation of the butterfly valve The compressor makes an excessive noise when running Replace compressor Servicing 3 Fitting instructions 1 Inlet temperature s
3. 1 1 1 2 1 3 1 4 LABPLANT 50 05 SPRAY DRYER SERVICE MANUAL Servicing Faultfinding Fitting instructions Settings and adjustments Appendix 1 Parts lists Appendix 2 Wiring diagrams 1 1 Service This procedure can be used as either a pre delivery inspection or as a guide to follow when performing a planned maintenance service 1 10 11 12 13 With all the glassware in position connect the unit to a suitable mains supply check that the mains on light operates Switch the unit on at the mains on switch allow time for the electronics to warm up 15 minutes Check that both the inlet and exhaust temperatures are approximately the same The temperature displayed should be the ambient temperature within the area in which the spray dryer is sited Switch on the peristaltic pump using the green touch contact select the pump flow reading using the multi indicator switch The pump flow is indicated on a scale of 10 to 50 on the display adjacent to the multi indicator switch A Rotate the pump speed knob until the display reads O the Pump should stop B Check that the speed of the pump changes as the pump speed knob is rotated Turn off the pump Switch on the blower using the green touch contact select the air flow reading using the multi indicator switch The air speed is indicated on a scale of 10 to 50 on the display adjacent to the multi indicator switch Use the
4. artment 7 Turn the unit on to its side to allow access to the 4x M4 compressor retaining bolts 8 Remove all 4 bolts and withdraw the compressor from the unit Fittina a new compressor 1 The new compressor is fitted using a reversal of the removal procedure Servicing 4 Settings and adjustments 1 Air flow 2 Air pressure Regulator adjustment 3 Peristaltic pump 4 Cal temperature controller settings All setting are as factory default except the following LEVEL 2 INPUT K 2 UNIT 2 HI SC 270 3 SP1 D SSD 1 BAND 47 1 INT T 0 8 1 DER T 4 1 CYC T 1 0 2 SP2 A DUHI 1 SET 2 10 3 UER Hold up down button until LOCK appears 5 Press down button until NO AL appears Change to ON Low mains voltage supply The SD 05 can be run successfully an 210 to 250 Volts A C Outside these limits the unit will malfunction If however the supply tends to be less than 220 Volts an alteration to the wiring of an internal transformer will improve the performance of the equipment To rewire the transformer 6 10 11 12 1 Disconnected the power from the unit and isolate fully before commencing any work described below Open the units side door using the triangular key Remove the 8 screws securing the electrical compartment cover using a 2 5mm Allen key Remove the cover after disconnecting the earth tag Remove and move aside the three PCBs mounted on the motherboard without disconnecting th
5. e pipes The transformer to be modified is the smaller of the two mounted to the left of the three PCBs Slide the plastic terminal cover over the wires to gain access to the connections Unsolder the two wires on the top tag marked xxx and re solder them to the next solder tag See the diagram below Replace the plastic terminal cover and the PCBs reseal the electrical compartment and replace the door 10 Appendix 1 Parts lists Power supply P C B fo Code Ns Qty 3 Qty 101 102 Bridge Rectifer 2KBB40 2 1 524 E Pu2 Comector 32way Transistor mounting kit Heatsink See Brg LOAD ee Signal conditioner P C B SD 05 Signal conditioner RV20I 202 43P 100K C201 204 juF 35V tantalum C205 208 100nF 63V tantalum 11 IC201 202 Amplifier INA102KP 2 S201 Gauge transducer UR transducer Ris Comector 32 way 7220229 10 way test socket 1 Bracket See drg 1 0540 1 Pte socket Bway tp dil socker 2 dil socker 2 28 17593isu 1 50 05 Pump motor 308 313 Resistor 55 10K 6 RGAGIS Resistor 98502 2 Resistor 850 ROSS 1 rRva01 302 Trimmer 2 Trimmer C301 Capicitor 100nF 3Vpoly 1 lt Capicitor 2 2uF 50Velect 1 303 304 Capicitor _10nF 63V poly 2 diode mas
6. ensor Removal of existing temperature sensor 1 Disconnected the power from the unit and isolate fully before commencing any work described below 2 Remove all the glassware from the unit 3 Open both doors using the triangular key Disconnect the earth tags and pull up the spring bolts to remove the doors 4 Remove the 8 screws securing the electrical compartment cover using a 2 5mm Allen key Remove the cover after disconnecting the earth tag 5 Carefully remove the insulation from around the bend at the top of the heater column so that the input temperature probe and the over temperature sensor are exposed 6 Separate the thermocouple temperature probe wire from the over temperature probe capillary tube 7 Inside the electrical compartment disconnect the thermocouple wires from the CAL temperature controller contacts 1 amp 2 8 Pull the cable out through the grommet in the back of the electrical compartment 9 Slacken the grub screw holding the sensor in position and remove the sensor from its housing If the grub screw has been over tightened it may be necessary to destroy the sensor in order to remove it Fitting a new sensor 1 Thread the thermocouple cable through the grommet on the case and connect the cable to the CAL controller 2 Carefully fit the thermocouple into position in the inlet manifold 3 Tighten the grub screw so that it just nips the thermocouple case taking care not to crush the stainl
7. ess tube The thermocouple should protrude into the air stream by approximately 15 to 20 mm 4 Secure the thermocouple cable to the capillary tube and replace the insulation around the inlet manifold 5 Replace the electrical compartment cover and the doors ensuring that all the earth tags have been reconnected 2 Exhaust temperature sensor Removal of the existing sensor 1 Disconnected the power from the unit and isolate fully before commencing any of the work as described below 2 Remove all the glassware from the unit 3 Open both doors using the triangular key Disconnect the earth tags and pull up the spring bolts to remove the doors 4 Using an 2 5mm Allen key remove the 8 screws securing the electrical compartment cover 5 On the outside of the machine remove the covers on the sliding glass support head Inside this head the thermocouple and the outlet pressure detector can be seen 6 Loosen the grub screw holding the thermocouple and carefully withdraw it through the bottom of the bracket 7 Thread the thermocouple back into the case and through the grommet in the control box 8 Unclip the thermocouple leads from the cable tie securing them to the motherboard 9 Unplug the 2 way connector from the motherboard Refitting the probe 1 Connect the 2 way plug to the motherboard fasten the thermocouple leads to the pillar using a cable tie 2 Thread the thermocouple through the grommet on the case
8. green up button to increase the air flow to its maximum NB Maximum flow has been reached when the display ceases to increase If the machine is cold the meter reading will stop at approximately 46 With the airflow set to maximum switch on the heater using the green touch contact Set the inlet temperature to 100 C on the CAL temperature controller Check that when the set temperature has been reached it remains stable Turn off the both the blower and the heater Red touch switches Switch the multi indicator switch to compressor air flow The air pressure in bars will be indicated on the display adjacent to the multi indicator switch Switch on the compressor using the appropriate green touch switch Using the compressor air pressure control set the air pressure to maximum Using the de blocker control check that the frequency of the de blocking device can be adjusted Check all the glassware for damage and clean the machine as necessary Servicing 2 Fault Finding When turned on at the mains the Mains on light does not illuminate Check the fuse in the main s plug Check the line fuse F1 situated next to the main s inlet Check the mains on indicator L1 The inlet and exhaust temperatures are not the similar Are either approximately the same as the ambient temperature Disconnect the sensor which is giving the incorrect reading Connect a new sensor and check that the displays are now similar If the temperatures
9. h tag Disconnect the heater wiring from inside the electrical compartment Carefully remove the insulation from around the heater and disconnect the heater from the flow control valve body by slackening the 3 accessible grub screws on the control valve flange Remove the air blower assembly as section 3 Withdraw the heater from the inlet manifold Fitting a replacement heater 1 5 Slide the replacement heater into the inlet manifold and refit the blower motor assembly Reconnect the heater to the flow control valve Fit the heater wires back into the electrical compartment Replace the insulation around the heater Rewire the heater before replacing the electrical compartment cover and doors ensuring that all the earth tags have been reconnected Compressor Removal of existing compressor 1 Disconnected the power from the unit and isolate fully before commencing any work described below 2 Remove all the glassware from the unit 3 Open both doors using the triangular key Disconnect the earth tags and pull up the spring bolts to remove the doors 4 Remove the 8 screws securing the electrical compartment cover using a 2 5mm Allen key Remove the cover after disconnecting the earth tag 5 Pull out and remove the two pipes leading away from the compressor 6 Remove the plug SK9 from the electrical motherboard and cut the cable tie to allow the compressor power lead to be removed from the electrical comp
10. rol valve from the blower flange noting the orientation of the valve motor to the fan housing Remove the two feet complete with studs from the air blower motor noting the position of the feet in respect to the blower assembly Fitting a replacement air blower and motor 1 Check that the alignment of the new unit s blower flange is correct 2 Remove the foot plate from the motor and replace with the feet removed from the old unit Note In order for the air blower and motor assembly to be correctly aligned with the heater the feet should be fastened on the motor so that the centre of the first stud is 65mm from the fan casing 3 Fasten the flow control valve to the air blower flange making sure that the valve motor is in its correct position 4 Fit the assembly back into the unit making sure that the flow control valve mates correctly with the heater 5 Replace the electrical compartment cover and the doors ensuring that all the earth tags have been reconnected 4 Air heater Removal of the existing air heater 1 Disconnected the power from the unit and isolate fully before commencing any work described below 2 Remove all the glassware from the unit 3 Open both doors using the triangular key Disconnect the earth tags and pull up the spring bolts to remove the doors 4 Remove the 8 screws securing the electrical compartment cover using a 2 5mm Allen key Remove the cover after disconnecting the eart
11. where the other thermocouple wire passes through 3 Pass the thermocouple through the case and carefully fit the thermocouple tip into its hole on the bracket 4 Tighten the grub screw so it just nips the thermocouple case taken care not to crush the stainless tube The thermocouple should protrude into the exhaust tube the same distance as the outlet pressure pipe approx 15 to 20 mm 5 Replace the electrical compartment cover and the doors ensuring that all the earth tags have been reconnected 3 Air Blower Removal of the existing air blower 1 10 Disconnect the power from the unit and isolate fully before commencing any of the work as described below Remove all the glassware from the unit Open both doors using the triangular key Disconnect the earth tags and pull up the spring bolts to remove the doors Remove the 8 screws securing the electrical compartment using a 2 5mm allen key Remove the cover after disconnecting the earth tag Remove the plug SK8 from the electrical motherboard and cut the cable tie to allow the blower power lead to be removed from the electrical compartment Remove the power lead from the butterfly valve motor 2 x push on tags Disconnect the heater from the flow control valve body by slackening the 3 accessible grub screws on the control valve flange Undo the 4 motor retaining nuts and remove the blower assembly With the fan assembly removed from the unit remove the flow cont
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