Maintenance works: W 0704 M0

Gas-mixer

Turn off motor according to technical instruction no. 1100-0105 and secure against unauthorized
restart.

Interval every
Maintenance works 10000 Oh 20000 Oh 30000 Oh
10 Replace the circuit board and the rubber
„
sleeve
20 Replace the servomotor „
20/30 Overhaul „ *) „

*) only for B15, B16, B17, B21, B27, special gasses, hot cooling 95 – 110 °C

Disassembly:
Hexagon head cap screw 1, Remove cover 2 and conical
nipple 3.
Switch off supply voltage to control motor and circuit board (i. e.
disconnect clamp of DM455 and withdraw fuse from module
interface).

Disassemble the circuit board and servomotor and replace

these.

Issued: Doku./Bilek Checked: Entwicklungsgruppe B Date: 2002-04

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 Maintenance works: W 0704 M0
Gas-mixer

Remove hexagon nut 4, discs 5 and threaded rod 6.

Remove steel plate.

Turn the circuit-board shaft of the gas mixer in the

direction "AUF" (open) (20 mA).
Switch on supply voltage to control motor and circuit
board (connect clamp of DM455 and insert fuse into
module interface).
Caution: danger of short-circuit
The control motor will unscrew itself out of the gas-mixer
shaft (if the motor does not run, check whether the
Auto/Man button in dia.ne (screen 41) is set to 'Auto',
turn the potentiometer in the direction of
"ZU"(shut)(4 mA), and subsequently in the direction of
"AUF" (open) (20 mA)).
Switch off supply voltage to control motor and circuit W0704 35

board again.
Remove wiring from control motor and circuit board.

Issued: Doku./Bilek Checked: Entwicklungsgruppe B Date: 2002-04

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 Maintenance works: W 0704 M0
Gas-mixer

Layout of cables:

W0704-36

Name Stepping motor R/I converter plate Simulation device

Motor phase 1 (+) Ph1+ (green) 1 (green) 11 (green)
Motor phase 1 (-) Ph1- (red) 2 (red) 12 (red)
Motor phase 2 (+) Ph2+ (black) 3 (black) 21 (black)
Motor phase 2 (-) Ph2- (grey) 4 (blue) 22 (blue)
+ 24 V IN 1 (yellow) 30 V (yellow)
+ mA OUT 2 (black) Iein
Schirm 3 (Schirm) no connection
Attention: The colours of the cores might change according to the manufacturer!

Inspection:
Check if the gas mixer shaft can be easily moved in the gas mixer case.
(Check: slide the motor forward and back while it screws itself out of the gas-mixer shaft.)
Check shaft and setting thread for wear. Replace, if necessary.
Relubricate the adjusting screw thread and apply a small amount of grease to the shaft.

Assembly:
Assemble the spring to the new
servomotor.

Connect the cabling of the servomotor and

the circuit board. Turn the circuit-board
shaft of the gas mixer in the direction "ZU"
(shut) (4 mA).
Switch on the power supply of the
servomotor and circuit board again. Fit the
servomotor into the screw thread by hand.
The motor will screw itself into the gas-
mixer shaft and open until it reaches the W0704 37

mechanical stop. Switch off the power

supply of the motor and circuit board
again. To continue the assembly, follow
the disassembly procedure in reverse
order.
Do not assemble the circuit board yet.

Issued: Doku./Bilek Checked: Entwicklungsgruppe B Date: 2002-04

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 Maintenance works: W 0704 M0
Gas-mixer

Adjusting the 0% position:

Turn the circuit-board shaft in the direction "AUF" (open) (20 mA) until it reaches the mechanical stop.
Switch on the power supply of the motor and circuit board. The gas mixer closes until it reaches the
mechanical stop. Switch off the power supply of the motor and circuit board again. Turn the circuit-board
shaft in the direction "ZU" (shut) (4 mA) until it reaches the mechanical stop (now the mixer is "ZU" (shut)
(0%) and the potentiometer is "ZU" (shut) (4mA)).
Assemble the circuit board with the potentiometer shaft on the servomotor (there are two types: circuit
boards with a ribbed potentiometer shaft and circuit boards with a smooth potentiometer shaft).

Assembling circuit boards with a ribbed potentiometer shaft:

The ribbed potentiometer shaft prevents the shaft from sliding in the rubber sleeve. Insert the new rubber
sleeve into the transmission unit leaving only approx. 1 mm of the rubber sleeve sticking out from the
blind hole. Insert the circuit board with potentiometer shaft into the rubber sleeve. Assemble the circuit
board using 4 M4 nuts. Lock the M4 nuts using locking paint.

Assembling circuit boards with a smooth potentiometer shaft:

Glue the new rubber sleeve onto the potentiometer shaft using Loctite 454 glue to prevent the
potentiometer shaft from sliding in the rubber sleeve. Before gluing the rubber sleeve to the potentiometer
shaft, make sure to carefully remove all the white powdery deposit in the rubber sleeve which was left
behind during its manufacture. Slide the rubber sleeve onto the potentiometer shaft. Lift the rubber sleeve
at the front from the shaft using a flat screwdriver. Insert a drop of super glue into the opening created
and move the screwdriver one full turn around the potentiometer shaft (to make sure that the glue is
evenly spread along the front part of the rubber sleeve and to prevent glue from entering the
potentiometer). The curing time of the glue is 2 minutes. Slightly press on the potentiometer to insert the
circuit board with potentiometer shaft into the blind hole. Assemble the circuit board using 4 M4 nuts.
Lock the M4 nuts using locking paint.
Switch on the potentiometer supply voltage.

The rest of the assembly is carried out in reversed order of the disassembly.

4, 5, 6
2, 3

Issued: Doku./Bilek Checked: Entwicklungsgruppe B Date: 2002-04

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