Retsch ZM 200 Operating instructions

© Retsch GmbH, 42781 Haan, Retsch-Allee 1-5, Germany
Version Q25.08.2015
Repair Manual for Rotor Mills
Ultra-Centrifugal Mill ZM200

2
Copyright
Copyright by
Retsch GmbH
Retsch-Allee 1-5
D-42781 Haan
Germany

3
1Notes on the Repair Manual ..................................................................................................................5
1.1 General Points................................................................................................................................... 5
1.2 Important instructions for all repair work............................................................................................ 5
1.3 Necessary documents....................................................................................................................... 5
1.4 Tools.................................................................................................................................................. 5
1.5 Returned goods delivery note/declaration of safeness ..................................................................... 6
2Packaging, Transport and Set-Up.........................................................................................................8
3Disassembly, Assembly and Repair Instructions ...............................................................................9
3.1 Taking off the Housing....................................................................................................................... 9
3.1.1 Required tools:............................................................................................................................... 9
3.1.2 Required spare parts::................................................................................................................... 9
3.1.3 Description of procedure................................................................................................................ 9
3.2 Instructions for Adjusting Trunnions ................................................................................................ 11
3.2.1 Required tools:............................................................................................................................. 11
3.2.2 Description of the procedure........................................................................................................ 11
3.3 Replacing the Control PCB GP2 ..................................................................................................... 14
3.3.1 Required tools:............................................................................................................................. 14
3.3.2 Required spare parts:.................................................................................................................. 14
3.3.3 Description of the procedure........................................................................................................ 14
3.4 Replacing the Frenic-Mini Frequency Converter............................................................................. 17
3.4.1 Required tools:............................................................................................................................. 17
3.4.2 Required spare parts:.................................................................................................................. 17
3.4.3 Description of the procedure........................................................................................................ 17
3.5 Replacing the Siei Frequency Converter with a Frenic-Mini FC...................................................... 20
3.5.1 Required tools:............................................................................................................................. 20
3.5.2 Required spare parts:.................................................................................................................. 20
3.5.3 Description of the procedure........................................................................................................ 20
3.6 Replacing the Display...................................................................................................................... 25
3.6.1 Required tools:............................................................................................................................. 25
3.6.2 Required spare parts:.................................................................................................................. 25
3.6.3 Description of the procedure........................................................................................................ 25
3.7 Replacing the Fan............................................................................................................................ 26
3.7.1 Required tools:............................................................................................................................. 26
3.7.2 Required spare parts:.................................................................................................................. 26
3.7.3 Description of the procedure........................................................................................................ 26
3.8 Replacing the Motor-Driven Lid Lock .............................................................................................. 27
3.8.1 Required tools:............................................................................................................................. 27
3.8.2 Required spare parts:.................................................................................................................. 27

4
3.8.3 Description of the procedure........................................................................................................ 27
3.9 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:.............................................................................................................. 31
3.10.3 Procedure ................................................................................................................................ 31
3.11 Error Messages ............................................................................................................................... 33
4Drawings ...............................................................................................................................................35
4.1 Views of the Device......................................................................................................................... 36
4.2 Circuit diagram for the device.......................................................................................................... 45
5Changes ................................................................................................................................................47
6Index ......................................................................................................................................................48

5
1 Notes on the Repair Manual
1.1 General Points
This repair manual for the tap sieving machine contains all the information
necessary for the areas specified in the table of contents.
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
or contact Retsch GmbH directly:
Retsch GmbH
Retsch-Allee 1-5
42781 Haan / Rhl.
Germany
1.2 Important instructions for all repair work
The following tests must be conducted every time repairs are done:.
•...
•...
•...
The permissible measurements can be found in the test instructions for the device.
1.3 Necessary documents
Repair Manual
Operating Instructions
Test Instructions
1.4 Tools
The following tools should be ready to hand:

Notes on the Repair Manual
6
03.025.0042
83.009.0027
83.009.0029
USB cable
Adjusting device
Pronged wrench A/F 30
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
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.
Before the machine is repaired, have your customer fill in the following Returned
Goods Delivery Note and issue a Declaration of Safeness. This protects you from
any harmful grinding residue in the machine.

Notes on the Repair Manual
7
Please stick this declaration onto the outside of the packaging!
Returned goods delivery note/declaration of safeness
We endeavour to fulfil your wishes quickly and specifically and also to protect the health of our employers. Please understand therefore
that the RETSCH device and the corresponding accessories can only be accepted for repair, maintenance or calibration if this
document is filled in correctly and completely. Otherwise, we reserve the right to refuse to accept the delivery and to return it at the
sender’s expense.
1. Details of your RETSCH device and accessories:
Designation:
Article and serial number:
Which accessories are used with the device? (Please enclose details on applications too if you wish).
2. Reason for the return (including description of fault):
Do you require a cost estimate (subject to a charge)?: yes no
3. The following materials were prepared with the device:
I/we assure that the RETSCH device and/or the corresponding accessories in the consignment were properly
cleaned:
3.a The materials in any residual contamination are harmless for anyone coming in contact with them.
3.b We cannot confirm that residual contamination will not present risks to health and we recommend the following
preventative safety measures (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.
Place/date Legally binding signature
Please enter your contact details here:
Company/Institute:
Department:
Person to contact:
Road:
Postcode/city:
Phone/fax:
E-mail:
FB-S+E-807-003_D_ Change Status B 12/2006

Packaging, Transport and Set-Up
8
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. It conforms to the
generally applicable packaging guidelines.
NOTE
Storage of packaging
–In the event of a complaint or return of goods, unsuitable packaging or
inadequate safeguarding for the machine can jeopardize your warranty
claims.
•Please retain the packaging for the duration of the warranty period.
NOTE
Electrical connection
–Mechanical or electronic components can become damaged.
•Observe the specifications on the type plate.
•
•
•.
•Please check the type plate for details on the necessary voltage and
frequency for the device.
•Make sure the levels agree with the existing mains power supply.
•Use the supplied connection cable to connect the device to the mains power
supply.
CAUTION
When connecting the power cable to the mains supply, use an external fuse that
complies with the regulations applicable to the place of installation. .

Disassembly, Assembly and Repair Instructions
9
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
Use the socket wrench to loosen the hexagonal
screws on the base plate. If the housing lid was closed normally (without
electrical power), use the provided hex key to open
the housing lid.
Hexagonal screws
4.2 x 19

Disassembly, Assembly and Repair Instructions
10
To unlock the closure gear, insert the key
and then push it in further with some degree
of force.
As you push the key in, turn it in a clockwise
direction as far as it will go.
The lid can be opened now.
Now remove the labyrinth disc. Remove the black cover caps on the motor
flange and loosen the 4 screws on the motor
flange.
Now pull the rotary knob off the control
display.
Remove the housing. Pull it up carefully and
straight. When putting it back on, make sure
the housing is guided in the rear panel.

Disassembly, Assembly and Repair Instructions
11
3.2 Instructions for Adjusting Trunnions
3.2.1 Required tools:
Calliper gauge
83.009.0030 Adjusting device
3.2.2 Description of the procedure
Switch on the device and open the lid. Put the
labyrinth disc along with the O-ring and the cassette
base onto the ZM200.
Press the inside of the brass adjusting device out as
far as it will go.

Disassembly, Assembly and Repair Instructions
12
Put the adjusting device on in the same way as
you would a ring sieve. In doing so, make sure the
slit is pointing forwards. The test device cannot be
rotated, it rests in a straight position and does not
wobble.
Close the housing lid slowly and carefully and make
sure that the closure grips the lid. It is important not
to let the lid drop or close with a jerk.
Open the ZM200 and carefully take out the test
device. . Use a calliper gauge to measure the
space between the brass disc and the supporting
surface. The measurement to be set is 29.4mm
+0.1 mm.
To adjust the trunnion, first release the lock nut by
means of the A/F 30 open-end wrench or an A/F 30
special wrench. The trunnion with the nut at the
back can then be unscrewed or screwed in. If the
measurement read is greater than 29.5, the
trunnion must be screwed inwards towards the
housing lid. If the measurement read is less than
29.4, the trunnion must be unscrewed outwards
from the housing lid.
Tighten the lock nut for the trunnion again!

Disassembly, Assembly and Repair Instructions
13
Repeat the adjusting procedure until the
measurement is between 29.40mm and 29.50mm. At the end, check if the lock nut is tight.

Disassembly, Assembly and Repair Instructions
14
3.3 Replacing the Control PCB GP2
These instructions describe how to replace the control board GP2 as of amendment index “I”
After exchange, check the interfaces are functioning properly and replace the identification plate to a new
one.
3.3.1 Required tools:
Allen key 2,5mm
Allen key 4mm
Phillips head screwdriver
Hexagonal socket wrench A/F 7
3.3.2 Required spare parts:
05.748.0179 control board GP2
or 05.748.0179 control board GP2 for TFT display
4 x 05.009.0060 cover cap
3.3.3 Description of the procedure
Disconnect the ZM200 from the mains supply and
open the housing. Take all connectors off the control
PCB.
Use an Allen key to loosen all 6 screws fastening the
control PCB to the component carrier.

Disassembly, Assembly and Repair Instructions
15
Old control board GP New control board GP 2
Remove the control PCB and replace it with a new
one. Mount the new control PCB onto the component carrier. It is important to use all 6 screws.
Now connect all plug-in contacts. Use the enclosed
circuit diagram as an aid. . Take care about the two bridges for the safety scan this is not required for the ZM200.

Disassembly, Assembly and Repair Instructions
16
Now connect all plug-in contacts.
The interface function USB and colour display are not activatied yet.
Secure the interface connection RS485 into the
cabel channel it is no longer necessary. Assemble the housing and check that the interface are functioning properly.
Display Speed sensor
RS 232
DR100
Interlock
Fan
USB
Colour display connection

Disassembly, Assembly and Repair Instructions
17
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. Ultra Centrifugal Mills with the lower change index H need the
conversion set 02.199.0009 as described in Chapter 3.5.
Disconnect the ZM 200 from the mains supply and
open the housing. Remove the patch cable from the control PCB to the frequency converter.

Disassembly, Assembly and Repair Instructions
18
Disconnect the frequency converter from the brake
resistors, motor and power supply and take it out. Place the new frequency converter on the base plate and screw it in using the existing screw holes.
Connect the connection cables in accordance with
the terminal assignment described in the circuit
diagram.
Put the interface card downwards onto the
frequency converter. Take special care with the
contacts!
Plug the interface cable onto the interface card. Insert the other end of the interface cable into the
control PCB.

Disassembly, Assembly and Repair Instructions
19
Put some talcum powder onto the rubber seal, in
particular on the vertical surface and assemble the
machine again completely.

Disassembly, Assembly and Repair Instructions
20
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
3.5.3 Description of the procedure
NOTE: This guide describes how to replace a defective Siei frequency converter for ZM 200 Ultra
Centrifugal Mills with an index lower or equal to change index H.
Disconnect the ZM 200 from the mains supply and
open the housing. Take out the display, display
holder and the rear wall.
Take the connectors, main switch, frequency
converter and the housing fan off the old rear wall.