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Dr. Bruno Lange GmbH & Co.

KG

Service Manual

LT 200 / DRB 200

DOC222.52.00609.Mar05
HACH LANGE GmbH Postfach 27 02 47 D-40525 Dsseldorf

Service Dsseldorf: Bongert, Willms, Krou, Heger


ServiceSupport Volker Maue

VM
CC: Mller-Kemsa
+49 (0) 211 5288-375

+49 (0) 211 5288-289

volker.maue@hach-lange.de

10.03.2005

Service Information
Bitte aktualisieren Sie Ihre Serviceunterlagen!
Please update your service manuals!

Thermostat LT 200 / DRB 200 Software Version 1.3.3


Bei einigen Thermostaten gab es Ausflle mit dem Fehler Init Error und defekten Heizfolien. Deswegen
wurde die Software mit folgenden nderungen verbessert:
Verbesserung der Spannungserkennung in der Initialisierungsphase
Men fr Dauertest eingefgt (im erweiterten Testprogramm Burn in Test) nur fr die Produktion
Einfhrung eines Auslieferungsstatus Sprachauswahl erscheint beim erstmaligen Einschalten (im
erweiterten Testprogramm - Supply Defaults Set) nur fr die Produktion

Das Softwareupdate sollte nur auf Gerten erfolgen, welche sich zur Reparatur in der Serviceabteilung
befinden. Es sollen keine funktionsfhigen Thermostate mit der neuen Software aktualisiert werden!

Achtung: Das Softwareupdate erfolgt nur im Servicecenter in Dsseldorf! Alle anderen


Serviceabteilungen tauschen bitte die Rechnerkarte aus!

Seit Ende 2004 gibt es 3 zustzliche Varianten des LT 200 bzw. DRB 200:
LTG082.xx.23000 LT 200 9x13 / 6x13mm + 9x13 / 6x13mm
LTG082.xx.51000 LT 200 6x13 / 4x20mm + 6x13 / 4x20mm
LTG082.xx.44001 DRB 200 9x16 / 6x16mm + 9x16 / 6x16mm

As some customers had problems with the reactor LT 200 / DRB 200 (error message Init Error, defective
heating foils), we modified the software with following improvements:
Better recognition of main voltage during the initialization
Insert a long time heating test (advanced test program Burn in Test) only for production
Insert a start-up mode after the first power on a language selection appears (advanced test program
Supply Defaults Set) only for production

Please update only the devices which are being repaired in the service department! Please dont update
devices which are still in working order!

Note: The upgrade of the new software version only take place at our service department
in Dsseldorf! All other service departments should replace the digital board!

Since the end of 2004 some additional version of LT 200 / DRB 200 are available:
LTG082.xx.23000 LT 200 9x13 / 6x13mm + 9x13 / 6x13mm
LTG082.xx.51000 LT 200 6x13 / 4x20mm + 6x13 / 4x20mm
LTG082.xx.44001 DRB 200 9x16 / 6x16mm + 9x16 / 6x16mm

Volker Maue
BU Lab Photometer

Softwareupdate LT 200 / DRB 200

1. Hilfsmittel
PC mit Betriebssystem Windows 9x / Me / NT / 2000 / XP und serieller Schnittstelle
Programm Flip (Atmel)
Konfigurationsdatei "LT200.cfg"
Datei "YYX471.hex"
Achtung: Die komplette Software ist im Intranet im Men Service / Software verfgbar!

Service-Adapter VAA564
Schnittstellenkabel, Nullmodemkabel gekreuzt, Dr.Lange Bestell-Nr. LZV087

2. Vorbereitende Ttigkeiten
Programm Flip aus zip-Datei auspacken und auf in einem Ordner abspeichern

3. Update
LT 200 / DRB 200 ffnen
Auf der Rechnerplatte ZBA719 den gewinkelten 8-poligen Stecker des Serviceadapters VAA564 wie im
Bild dargestellt aufstecken
Das Nullmodemkabel zwischen den Service-Adapter und der seriellen Schnittstelle COM1 des PC's
anschlieen (siehe Grafik)

LT200 / DRB 200

ZBA719

PC
Service-
RS232 Adapter
COM1 Kabel VAA564
LZV087

Den gelben Taste am Service-Adapter drcken und den Thermostaten einschalten


Im Display des Thermostaten erfolgt keine Anzeige
Taster wieder loslassen und am PC das Programm flip.exe starten
Im Men File den Punkt Read Configuration File auswhlen (siehe Bild)

Datei "LT200.cfg" auswhlen (siehe Bild)


den Button Run anklicken (siehe roter Kreis im Bild)

die Schritte Erase, Blank Check, Program und Verify werden automatisch nacheinander abgearbeitet
(siehe Bild)
Programm Flip beenden
Thermostat ausschalten
Service-Adapter entfernen
Thermostat einschalten
Softwareversion kontrollieren, wird whrend der Initialisierungsphase angezeigt
Software update LT 200 / DRB 200

1. Aids
PC or notebook with Windows 9x / Me / NT / 2000 / XP and serial port

Program Flip (Atmel)


Configuration file "LT200.cfg"
File "YYX471.hex"
Note: These files are available as download in our Hach-Lange Intranet, menu Service/Software.

Service adapter VAA564


Null modem cable, Dr.Lange order no. LZV087

2. Preliminaries
Unzip program Flip and save all files in a separate folder

3. Update
Open the thermostat LT 200 / DRB 200.
Connect the service adapter VAA564 to the digital board ZBA719 (see photo).

Connect the null modem cable LZV087 between service adapter and PC serial port COM1 (see graphic).

LT200 / DRB 200

ZBA719

PC
Service-
RS232 Adapter
COM1 Cable VAA564
LZV087
Press the yellow switch of the service adapter and power on the thermostat.
Note: It does not appear any text on the display!
Release switch and start the program flip.exe.
In the menu, select File, Read Configuration File...F4 (see screenshot).

Select file "LT200.cfg" (see screenshot).

Start by clicking Run (see red circle on the screenshot).


The steps Erase, Blank Check, Program and Verify are carried out automatically in sequence (see
screenshot).

Exit program Flip.


Power off the thermostat.
Remove service adapter.
Power on the thermostat.
Check the software version, it appears during the initialization.
Content
1. General 2
1.1 Variants ............................................................................................................ 2
1.2 Technical data .................................................................................................. 4
1.3 Initializing for 115V / 230V mains voltage ........................................................ 5
1.4 Error messages ................................................................................................ 5

2. Settings 6
2.1 Language.......................................................................................................... 6
2.2 Contrast ............................................................................................................ 6

3. Test program 7
3.1 Loading the test program ................................................................................. 7
3.2 User interface ................................................................................................... 9
3.3 Set block type ................................................................................................... 9
3.4 Displaying the software version and block type ............................................. 10
3.5 Restore factory settings.................................................................................. 10

4. Temperature adjustment 11

5. Troubleshooting 15

6. Removing, fitting and repairing individual components 16


6.1 Overview......................................................................................................... 17
6.2 Opening the thermostat.................................................................................. 19
6.3 Top section of the enclosure .......................................................................... 20
6.4 Protective lid ................................................................................................... 20
6.5 Covers ............................................................................................................ 21
6.6 Digital board ................................................................................................... 21
6.7 Display............................................................................................................ 22
6.8 Touch-sensitive keypad.................................................................................. 23
6.9 Mains connector with switch, interference suppression filter ......................... 23
6.10 Powerpack board ......................................................................................... 24
6.11 Heating block, heating foil, temperature sensor........................................... 26

7. Spare parts 28

8. Inspection document 34

9. Circuit diagrams and component mounting diagrams 37

Dr. Bruno Lange GmbH & Co. KG 1. General 1


1. General

1.1 Variants
LT 200

Article no. LTG082.xx.10000 Openings: 9 x 13mm and 2 x 20mm

Article no. LTG082.xx.21000 Openings: 15 x 13mm


Openings: 6 x 13 and 4 x 20mm

2 1. General Dr. Bruno Lange GmbH & Co. KG


DRB 200

Article no. LTG082.xx.30001 LTG082.xx.40001:


Openings: 9 x 16mm and 2 x 20mm Openings: 15 x 16mm

Article no. LTG082.xx.42001 Openings: 15 x 16mm


Openings: 6 x 16 and 4 x 20mm

Dr. Bruno Lange GmbH & Co. KG 1. General 3


1.2 Technical data
Type Thermostat with one heating block or two separate heating blocks with integrated
protective lids for heating cuvette tests and reaction vessels
Temperature programs LT 200:
COD program (148C, 120 min)
100C program (100C, 30, 60, 120 min)
40C program (40C, 10 min) and
freely selectable from 37 to 148C (no cooling)

DRB 200:
TOC program (105C, 120 min)
100C program (100C, 30, 60, 120 min)
105C program (105C, 30, 60, 120 min)
150C program (150C, 30, 60, 120 min)
165C program (165C, 30, 60, 120 min)
and freely selectable from 37 to 165C (no cooling)
Time programs Freely selectable 0-480 min; acoustic signal after countdown to zero
Heating rate LT 200:
from 20C to 148C in 10 min (in conformity with DIN 38409-44)
DRB 200:
from 20C to 150C in 10 min
Temperature stability +/- 2C
Number of cuvettes LT 200:
LTG082.xx.10000: 9 x 13 mm diameter, 2 x 20 mm diameter
LTG082.xx.21000: left: 15 x 13 mm diameter
right: 6 x 13 mm diameter, 4 x 20 mm diameter

DRB 200:
LTG082.xx.30001: 9 x 16 mm diameter, 2 x 20 mm diameter
LTG082.xx.40001: 15 x 16 mm
LTG082.xx.42001: left: 15 x 16 mm diameter
right: 6 x 16 mm diameter, 4 x 20 mm diameter
Power requirements 115 / 230 V, +5%/-15%, 50 / 60 Hz, safety class I
Power input LTG 082.xx.10000, LTG082.xx.30001 / LTG082.xx.40001:
115 V: 300 VA; 230 V: 450 VA
LTG 082.xx.21000, LTG082.xx.42001: 115 V: 600 VA; 230 V: 900 VA
Safety tests CE, GS and cTUVus
Environmental Operating temperature: 10 - 45C
requirements Storage temperature: -40 - 60C
Relative humidity: max. 90%, non-condensing
Dimensions W x H x D: 250 x 145 x 310 mm
Weight LTG 082.xx.10000, LTG082.xx.30001 / LTG082.xx.40001: 2 kg (instrument only),
3.5 kg (with packaging)
LTG 082.xx.21000, LTG082.xx.42001: 2.8 kg (instrument only), 4.3 kg (with
packaging)
Warranty 2 years

4 1. General Dr. Bruno Lange GmbH & Co. KG


1.3 Initializing for 115V / 230V mains voltage
The thermostat is suitable for both 115V and 230V mains voltage. The software determines the correct
voltage setting automatically during the initialization phase. When the thermostat is switched on, the heating
block or, in the case of a two-block thermostat, the right heating block is heated for 5 seconds at full power
(both half-waves of the power supply are used). If the temperature change after 5 seconds is less than 3C,
the software assumes that the mains voltage is 115V. The heating foil is driven by the full wave of the 115V
power supply.

If the temperature change after 5 seconds is greater than 3C, the software assumes that the mains voltage
is 230V. In this case, the heating foil is driven by only every fourth wave of the 230 V power supply.

The heating foil can therefore be used with approximately the same power input at different mains voltages.
The right and left heating blocks of a two-block thermostat are driven alternately. This reduces the load on
the power supply network.

1.4 Error messages


Error message Explanation Response
Block too hot! After the thermostat is switched on, it is Allow the block to cool
Please Wait! heated for about 5 seconds to initialize it. Check temperature sensor
However, if the block temperature is Check powerpack board
greater than 160C before the heating
phase starts, this error message is
displayed.
A user program has been started but the
block temperature is higher than the
required temperature.
Init error Initialization could not be performed. The Check temperature sensor
thermostat is not heating up. Check heating foil
Check powerpack board
No amplifier adjust! Digital board has not These error Replace digital board
been adjusted messages are for use
No interface! No user interface has during production. Select user interface in advanced
been selected test program.
No block select! No block type has Select block type in advanced test
been selected program.
No block adjust! No temp. adjustment Select adjust temp. in test
has been carried out program.
No tuning left! The temperature adjustment was started but
not completed.
Initializing Initialization could not be carried out. Check temperature sensors
Overtemp. WAIT! Pt1 and Pt2
Check heating foil
Check powerpack board

Dr. Bruno Lange GmbH & Co. KG 1. General 5


2. Settings

2.1 Language
Press the left key, keep it held down and switch on.

Sprache
GB D

The following language options are available:

GB Great Britain
D Germany
F France
I Italy
E Spain
NL Netherlands
S Sweden
PL Poland

After a language has been selected, the initialization of the thermostat starts.

2.2 Contrast
Press the centre key, keep it held down and switch on.

Contrast 140
OK

The contrast can be adjusted with the left and centre keys. Press the right key to store the setting. The
initialization of the thermostat then starts.

6 2. Settings Dr. Bruno Lange GmbH & Co. KG


3. Test program

3.1 Loading the test program


There are a basic and an advanced test program.

The basic test program can only be used to adjust (calibrate) the temperature of the heating blocks. The
advanced test program can be used to specify the number of blocks and set the software to Dr. Bruno
Lange or Hach mode.

Basic test program


Press the right key, keep it held down and switch on.

Service

Temp. adjust
Start

Service
End

Temperature adjustment

Final inspection Main program


Start End

Only for Production!

Dr. Bruno Lange GmbH & Co. KG 3. Test program 7


Advanced test program
Press the right key, keep it held down and switch on. Then press the left key and keep it held down for about
10 seconds.

Service

Ampl. adjust User interface


Start Beep DBL Hach

Only for Production! Emits audible signal

Set block type Info


left right Show

Block left Block right


15 9+2 15 9+2

Info about block


selection and
software

Block left Block right


6+4 End 6+4 End

Temp. adjust Final inspection Service


Start Start End

Final inspection
Temp. adjustment Start End
Main program

Only for Production!

8 3. Test program Dr. Bruno Lange GmbH & Co. KG


3.2 User interface
In the User Interface menu of the advanced test program, the left key can be used to select DBL (Dr. Bruno
Lange) and the centre key can be used to select Hach. If DBL is selected, the time starts to count down to
zero immediately after the program starts. If Hach is selected, the time starts to count down to zero when
the selected temperature has been reached and the Start key has been pressed.

User interface
DBL Hach

Press the right key ( ) until the following menu appears.

Service
End

Press the left key (End).


The program branches back to normal mode.

Note: When DBL or Hach is selected, the temperature programs in the user menu revert to the
factory settings.

3.3 Set block type


In the Set block type menu in the advanced test program, the left key can be used to select the left block
type and the right key to select the right block type.

Set block type


left right

The following block types can be selected:

Block type LT 200 DRB 200


15 15 x 13mm 15 x 16mm
9+2 9 x 13mm + 2 x 20mm 9 x 16mm + 2 x 20mm
6+4 6 x 13mm + 4 x 20mm 6 x 16mm + 4 x 20mm

The selections can be saved by pressing the End key.

Block left
6+4 End

Dr. Bruno Lange GmbH & Co. KG 3. Test program 9


3.4 Displaying the software version and block type
In the Info menu of the advanced test program, the Show key on the left can be used to display the software
version and the selected block type.

Info
Show

For example:

DBL 15 6+4
V 1.2.2

DBL = Dr. Bruno Lange user interface


15 = Left block type 15 x 13mm
6+4 = Right block type 6 x 13mm + 4 x 20mm
V1.2.2 = Software version 1.2.1

Software history:

Version 1.2.2 First delivery Sep. 2003


Version 1.2.3 Default contrast changed, Error message "No interface" implemented (for production)
Oct. 2003

3.5 Restore factory settings


In order to restore the factory settings, DBL or Hach must be selected again in the User Interface menu.

See 3.2 User interface

10 3. Test program Dr. Bruno Lange GmbH & Co. KG


4. Temperature adjustment
General
The temperature adjustment is described for the double block (LTG082.xx.21000, LTG082.xx.42001).

Aids
Glycerol, anhydrous (reagent grade >99.5%), approx. 5ml
Laboratory thermometer ASTM 67C (range 95C 155C, resolution 0.2C, height 379mm)
Article-No.: VAA568
Pipette
Protective goggles
LT 200: Cuvette, outside diameter 13mm, Order no.: LCW906 (25 cuvettes)
DRB 200: Cuvette, outside diameter 16mm, Order no.: 2275800 (1 cuvette), 2275806 (6 cuvettes)

Preparation of the cuvette


LT 200: Mark the cuvette 62mm (+/-0.5 mm) from the base.
DRB 200: Mark the cuvette 56mm (+/-0.5mm) from the base.
Place the laboratory thermometer in the cuvette.
Use a pipette to fill the cuvette up to the mark with glycerol.

Note: The glycerol should be at room temperature!

Position of the cuvette


Second row from the front, in the middle (see in the diagram)

LT 200:
Article no. LTG082.xx.10000 Article no. LTG082.xx.21000

Dr. Bruno Lange GmbH & Co. KG 4. Temperature adjustment 11


DRB 200:
Article no. LTG082.xx.30001 Article no. LTG082.xx.40001

Article no. LTG082.xx.42001

Adjustment
Place the cuvette in the left block.

Take care: Wear protective goggles!


Hot glycerol could escape from the open cuvette.

Start the basic test program (see 3.1 Loading the test program):
Press the right key, keep it held down and switch on.

In the Temp. adjust menu, press the left key (Start)

Temp. adjust
Start

The thermostat heats both blocks to 100C.

23C 25C
120' 120'

12 4. Temperature adjustment Dr. Bruno Lange GmbH & Co. KG


When the block temperature reaches 100C the thermostat emits an acoustic signal.

100C 100C
110' 110'

Note: The temperature in the heating block and the cuvette is stable after about 25 minutes.

Please wait until the displayed time is below 95'!

Press the left key.

100C 100C
90' 90'

Use the left and centre keys (under the arrows) to set the value displayed by the laboratory thermometer
and press the right key (OK).

True value left


100.0 OK

Place the laboratory thermometer in the right block together with the cuvette and wait until the value
displayed by the laboratory thermometer is stable.
Press the right key.

100C 100C
90' 90'

Use the left and centre keys (under the arrows) to set the value displayed by the laboratory thermometer
and press the right key (OK).

True value right


100.0 OK

The corrected temperature is accepted after it has been confirmed by pressing the OK key. After the
correction has been carried out, check the desired temperature of 100C again with the laboratory
thermometer.

Take care: The 100C correction can only be carried out once per adjustment sequence.

Dr. Bruno Lange GmbH & Co. KG 4. Temperature adjustment 13


Press the centre key.

100C 100C
80' 80'

Press the right key (End).

Final inspection
Start _ End

If another temperature adjustment is necessary, press the left key (Start) in the next menu. If no further
correction is needed, press the right key ( ).

Temp. adjust
Start

Press the left key (End).

Service
End

The program branches back to normal mode.

The thermostat carries out the initialization.

Checking the temperature


Insert the laboratory thermometer in the thermostat together with the cuvette and heat to 100C in normal
mode. After about 25 minutes read the temperature shown by the thermometer. The tolerance of +/- 2C
should not be exceeded.

Cooling phase
At a room temperature of about 24C the cooling time:

from 148C 40C = 160 minutes


from 100C 40C = 125 minutes

14 4. Temperature adjustment Dr. Bruno Lange GmbH & Co. KG


5. Troubleshooting
The following table should serve as a troubleshooting aid. The identification of faults in individual
components is described in detail in section "6. Removing, fitting and repairing individual component".

Problem Fault identification


Display remains blank after the Measure mains voltage
thermostat is switched on. Press or replace the switch
Measure powerpack board voltage fuse F1 okay?
Check cable from powerpack board to digital board
Measure +5V on digital board
Replace the display
Replace the digital board
Thermostat does not heat up. Measure powerpack board voltage fuses F2, F3 okay?
Check heating foil
Check temperature sensor
Check cable from powerpack board to digital board
Replace the powerpack board
Replace the digital board
Thermostat heats up too far or not Carry out temperature adjustment
far enough. Check heating foil
Check temperature sensor
Check cable from powerpack board to digital board
Replace the powerpack board
Replace the digital board
Only the left heating block of a Check right temperature sensor
two-block thermostat is displayed. Check right heating foil
Check cable from powerpack board to digital board
Replace the powerpack board
Replace the digital board
The thermostat cannot be Cable between touch-sensitive keypad and computer - no contact
operated. Defective touch-sensitive keypad
Replace top section of enclosure, including touch-sensitive keypad
Replace the digital board

Dr. Bruno Lange GmbH & Co. KG 5. Troubleshooting 15


6. Removing, fitting and repairing
individual components

16 6. Removing, fitting and repairing individual components Dr. Bruno Lange GmbH & Co. KG
6.1 Overview
Outside view

1 Protective lid, transparent


2 Cover, black
3 Insulating mat
4 Top section of enclosure
5 Touch-sensitive keypad
6 Display
7 Digital board

Dr. Bruno Lange GmbH & Co. KG 6. Removing, fitting and repairing individual components 17
Inside view

1 Protective padding
2 Heating block
3 Interference suppression filter
4 Spacer
5 Powerpack board
6 Mains connector and switch
7 Bottom section of enclosure
8 Base of enclosure

18 6. Removing, fitting and repairing individual components Dr. Bruno Lange GmbH & Co. KG
6.2 Opening the thermostat
Unplug the thermostat.
Remove the seal from the base or push a Phillips screwdriver through it, and remove the 4 screws (see
1 in illustration)

Use a screwdriver to carefully bend inward the two locking hooks (see 2 in the illustration) on the base
and remove the top section of the enclosure.

Dr. Bruno Lange GmbH & Co. KG 6. Removing, fitting and repairing individual components 19
6.3 Top section of the enclosure
Remove the top section of the enclosure:
Open the thermostat (see 6.2 Opening the thermostat)
Disconnect the connector from the powerpack board (see 1 in the illustration)

Spare part:
LT 200: LZT038 Top section of enclosure (Lange) with touch-sensitive keypad
DRB 200: LZT039 Top section of enclosure (Hach) with touch-sensitive keypad

6.4 Protective lid


Remove the protective lids:
Half open the protective lid (about 45) and take hold above the external hinge, with your thumb inside
the protective lid.
Press your thumb against the inside of the protective lid and carefully bend it slightly open and lift it
forward out of its mount (see illustration).

Then raise the protective lid slightly and remove the other side from the mount.

Spare part:
LZT048 Protective lid, transparent

20 6. Removing, fitting and repairing individual components Dr. Bruno Lange GmbH & Co. KG
6.5 Covers
Open the thermostat (see 6.2 Opening the thermostat).
Remove the top section of the enclosure (see 6.3 Top section of the enclosure).
Remove the protective lids (see 6.4 Protective lid).
Remove the screws (1 and 2 in the illustration) and take out the covers.

Note: The insulating mats are not included in the spare part.

Spare part:
LT 200+DRB 200: LZT047 Cover without openings

LT 200: LZT041 Cover 9x13 2x20


LZT042 Cover 15x13
LZT043 Cover 6x13 4x20

DRB 200: LZT044 Cover 9x16 2x20


LZT045 Cover 15x16
LZT046 Cover 6x16 4x20

6.6 Digital board


Fault identification:
Measure the +5V DC on the digital board at connector P3, PIN2 = +5V, PIN3=GND (see illustration).

Dr. Bruno Lange GmbH & Co. KG 6. Removing, fitting and repairing individual components 21
Replacing the board:
Open the thermostat (see 6.2 Opening the thermostat).
Remove the top section of the enclosure (see 6.3 Top section of the enclosure).
Disconnect the ribbon cable from the two cable holders in the top section of the enclosure.

Take care: The connector of the ribbon cable (see 1 in the illustration) is soldered to the digital board
and cannot be disconnected there!

Disconnect the cable of the touch-sensitive keypad (see 2 in the illustration) from the digital board.
Remove the 4 screws (see 3 in the illustration).

Take care: The threaded sleeves under the screws may turn with the screws. Hold the threaded
sleeves in place with a 5.5 mm open-ended spanner!

Remove the digital board.

After replacement:
Power on the device
On the display of the thermostat appears " No interface!"
Press the key below "OK", the advanced test program appears
in menu User Interface select Hach or DBL, see 3.2 User interface
in menu Set block type select block type, see 3.3 Set block type
in menu Temp. adjust press Start, see 4. Temperature adjustment

Spare part:
YAB001 Digital board

6.7 Display
Fault identification:
Measure the +5V DC on the digital board (see 6.6 Digital board).
Set the contrast, see (2.2 Contrast).

Replacing the display:


Remove the digital board.
Remove the 4 threaded sleeves (see 1 in the illustration) with a 5.5mm socket spanner or open-ended
spanner.
Remove the display.

Note: After mounting a new display, do not tighten the threaded sleeves too firmly, as this could
cause them to be ripped out of the plastic.

22 6. Removing, fitting and repairing individual components Dr. Bruno Lange GmbH & Co. KG
Spare part:
YAB017 Display

6.8 Touch-sensitive keypad


Fault identification:
Check the keypad cable to ensure that there is a good connection with the digital board (see 6.6 Digital
board).

Replacing the keypad:


If the touch-sensitive keypad is defective, replace the complete top section of the enclosure together
with the keypad (see 6.3 Top section of the enclosure).

Spare part:
LT 200: LZT038 Top section of enclosure (Lange) with touch-sensitive keypad
DRB 200: LZT039 Top section of enclosure (Hach) with touch-sensitive keypad

6.9 Mains connector with switch, interference


suppression filter
Fault identification:
See 6.10 Powerpack board

Replacing the mains connector with switch:


Open the thermostat (see 6.2 Opening the thermostat).
Remove the top section of the enclosure (see 6.3 Top section of the enclosure).
Remove the nut (see 2 in the illustration) from the interference suppression filter (see 1 in the
illustration) with a 7mm open-ended spanner.

Push the interference suppression filter to one side and disconnect the cables connected to the mains
connector.
Press in the top and bottom locking hooks on the mains connector (see 1 in the illustration below) and
pull out the unit.

Note: Press in the bottom locking hook with an offset screwdriver or similar.

Dr. Bruno Lange GmbH & Co. KG 6. Removing, fitting and repairing individual components 23
Spare part:
LZT040 Mains connector with switch

6.10 Powerpack board


Method of functioning:

Section of the circuitry (double block)

Part 1:
The mains current is supplied to connector P4 of the powerpack board via the mains connector and the
interference suppression filter. The current passes through the fuse F1 (6.3A T) to the triacs V1 and V2. The
triacs are driven from the digital board via the optocouplers H1 and H2. The current from the triacs is
conducted through connectors P2 and P3 to the heating foils. Each heating foil is protected by a 3.15 A T
fuse (F2 and F3).

Part 2:
The mains current passes through the varistor R11 and the fusing resistor R5 to the bridge rectifier D1. The
pulsating direct current is smoothed by the capacitor C2 and applied to the internal switched mode power
supply (I4, L3 ...). The required +5V voltage is set with the help of the voltage drop over D4 and I1. The
current is smoothed with C3 and L2 and applied to the digital board through connector P1.

See 9. Circuit diagrams and component mounting diagrams

24 6. Removing, fitting and repairing individual components Dr. Bruno Lange GmbH & Co. KG
Fault identification:

Warning: When the thermostat is open and switched on, potentially lethal voltages are present
on the powerpack board and the heat sinks of the triacs!

Switch on the open thermostat.


Measure the following voltages at the measuring points shown in the illustration:

Measuring Cause of fault if no voltage is


Voltage Response
point present
12 115/230 V AC Mains input defective Replace mains connector and
Defective switch switch
Defective interference Check interference suppression
suppression filter filter
13 115/230 V AC Fuse F1 = 6.3A slow reacting/ Check heating foil
defective Replace powerpack board
24 115/230 V AC Fuse F2 = 3.15A slow reacting/
defective
25 115/230 V AC Fuse F3 = 3.15A slow reacting/
defective
67 + 5 V DC Switched mode mains power Replace powerpack board
supply defective

Replacing the powerpack board:


Open the thermostat (see 6.2 Opening the thermostat).
Remove the top section of the enclosure (see 6.3 Top section of the enclosure).
Unplug the infeed (see 1 in the illustration) and the two heating foil connectors (see 2 in the illustration).
Unplug the two temperature sensor connectors (see 3 in the illustration) while pressing the connector
latch.

Lift out the powerpack board.

Spare part:
YAB002 Double powerpack board
YAB016 Single powerpack board

Dr. Bruno Lange GmbH & Co. KG 6. Removing, fitting and repairing individual components 25
6.11 Heating block, heating foil, temperature sensor
Fault identification:
Two heating foils are bonded to each heating block. They are connected in series. Between them is a
thermal link (see illustration)

1 Heating foil
2 Heating foil
3 Thermal link
4 PT1000 temperature sensor
5 Temperature sensor connection
6 Heating foil connection
7 Spacer

Disconnect the connector for the heating foil (plug-in place HEAT 1 or HEAT 2 on the powerpack board)
and measure the resistance with a multimeter: approx. 43 Ohm

Disconnect the connector for the PT1000 temperature sensor (plug-in place Pt 1 or Pt 2 on the
powerpack board) and measure the resistance with a multimeter:

Temperature (C) Approx. resistance (Ohm)


0 1000
10 1039
20 1078
30 1116
40 1155
50 1194
60 1232
70 1271
80 1309
90 1347
100 1385
110 1423
120 1461
130 1498
140 1536
150 1573

Note: If a thermal link (resistance = infinite) or a heating foil or a temperature sensor is defective,
always replace the complete heating block!

Replacing the heating block, etc.:


Open the thermostat (see 6.2 Opening the thermostat).
Remove the top section of the enclosure (see 6.3 Top section of the enclosure).
Disconnect the connector of the powerpack board (see 6.10 Powerpack board).
26 6. Removing, fitting and repairing individual components Dr. Bruno Lange GmbH & Co. KG
Remove the interference suppression filter (see 6.9 Mains connector with switch, interference
suppression filter) and the grounding cable of the fixing screw.
Remove the 4 screws for the right (see 1 in the illustration) or the left heating block (see 2 in the
illustration).

Replace the complete heating block

Spare part:
LT 200: LZT032 Lange heating block, 9x13 2x20
LZT033 Lange heating block, 15x13
LZT034 Lange heating block, 6x13 4x20

DRB 200: LZT035 Hach heating block, 9x16 2x20


LZT036 Hach heating block, 15x16
LZT037 Hach heating block, 6x16 4x20

Dr. Bruno Lange GmbH & Co. KG 6. Removing, fitting and repairing individual components 27
7. Spare parts
LT 200 + DRB 200

Display Mains connector with switch


Order no.: YAB017 Order no.: LZT040

Powerpack board, double Powerpack board, single


Order no.: YAB002 Order no.: YAB016

Digital board Protective lid, transparent


Order no.: YAB001 Order no.: LZT048

28 7. Spare parts Dr. Bruno Lange GmbH & Co. KG


Cover without openings
Order no.: LZT047

Dr. Bruno Lange GmbH & Co. KG 7. Spare parts 29


LT 200
Cover 15x13 Cover 6x13 4x20
Order no.: LZT042 Order no.: LZT043

Cover 9x13 2x20 Top part of enclosure (Lange)


Order no.: LZT041 with touch-sensitive keypad
Order no.: LZT038

30 7. Spare parts Dr. Bruno Lange GmbH & Co. KG


Heating block (Lange) 9x13 2x20 Heating block (Lange) 15x13
Order no.: LZT032 Order no.: LZT033

Heating block (Lange) 6x13 4x20


Order no.: LZT034

Dr. Bruno Lange GmbH & Co. KG 7. Spare parts 31


DRB 200
Cover 15x16 Cover 6x16 4x20
Order no.: LZT045 Order no.: LZT046

Cover 9x16 2x20 Top part of enclosure (Hach)


Order no.: LZT044 with touch-sensitive keypad
Order no.: LZT039

32 7. Spare parts Dr. Bruno Lange GmbH & Co. KG


Heating block (Hach) 15x16 Heating block (Hach) 6x16 4x20
Order no.: LZT036 Order no.: LZT037

Heating block (Hach) 9x16 2x20


Order no.: LZT035

Dr. Bruno Lange GmbH & Co. KG 7. Spare parts 33


8. Inspection document

34 8. Inspection document Dr. Bruno Lange GmbH & Co. KG


Inspection document

Dear Customer
The company Dr. Bruno Lange GmbH, Germany, has introduced a quality system
according to DIN EN ISO 9001. Dr. Lange-Instruments are designed, produced and
serviced according to the requirements of this quality system. If using the service
regularly, you can be sure that you fullfill the requirements of your own quality system.
This servicing document helps you to document you control and inspection activities of
your measuring and the test equipment.

Name of Instrument:

Instrument-Type: LTG

Instrument-No.:

Results:
Keys ok

Display ok

Power supply ok

Timer ok

Temperature ok

Temperature heating block, left:


Nominal value 100 C 148 C
Tolerance + / - 2 C + / - 2 C
Actual value

Temperature heating block, right:


Nominal value 100 C 148 C
Tolerance + / - 2 C + / - 2 C
Actual value

Date:

Service engineer:

Signature:
9. Circuit diagrams and
component mounting diagrams

Dr. Bruno Lange GmbH & Co. KG 9. Circuit diagrams and component mounting diagrams 37
8 7 6 5 4 3 2 1

VCC

8
!"# 3
1
2
F
VCC VCC F

4
" "
GND GND
GND

GND

8
GND GND GND GND
3
1 &1 '
GND
$ % 2

1
GND
5

4
+
3 7 &1 '
n.c. GND
6

-
02 GND

2
GND
E
E
GND

GND
VCC VCC
GND
GND

VCC
L+
L-
GND
1
GND
2
VCC
!"# 3
( 4
( ) 5
( 6
(( 7
(( 8
D
41 30 (( 9
GND X1 P0.0/AD0
31 (( 10
P0.1/AD1 D
32 (( 11
P0.2/AD2
weder vervielfltigt noch Dritten zugnglich gemacht werden.

3 40 33 (( 12
VCC VCC GND X2 P0.3/AD3
Und sie darf durch den Empfnger oder Dritte auch nicht in

34 (( 13
P0.4/AD4
Ohne unsere vorherige Zustimmung darf diese Untelage

2 44 35 (( 14
RESET Reset P0.5/AD5
36
P0.6/AD6
1 VCC 37 ( ,-'./*
GND GND P0.7/AD7
anderer Weise mibruchlich verwertet werden.

5
3 29
4 2 P1.0-AN0 P2.0/AD8
GND 4 28
P1.1-AN1 P2.1/AD9
5 27
P1.2-AN2 P2.2/AD10

3
GND GND 6 26
P1.3-AN3 P2.3/AD11
7 25
VCC P1.4-AN4 P2.4/AD12
!"# 8 24 1

5
&* &*$
P1.5-AN5 P2.5/AD13
4 2 9 23 &* &*$ 2
GND P1.6-AN6 P2.6/AD14
1 10 22 &* &*$ 3
P1.7-AN7 P2.7/AD15
2 4
3
VCC
VCC
GND 3 11 21 5
GND EA P4.1
4 +( 12 20 GND 6
P3.0/RxD P4.0
C 5 +( 13 19 7
P3.1/TxD P3.7/RD C
6 &*$ 14 18 8
P3.2/INT0 P3.6/WR
7 &*$ 15
P3.3/INT1
8 &*$ VCC &&' 16 VCC /-"/"2#
P3.4/T0
17 2 $ %
P3.5/T1 VAREF GND GND GND
) 1
VAGND VCC
42
VCC VCC
38
PSEN GND
39 VCC
ALE
43
GND GND
GND
VCC

1
2
GND
3
B 4
5 GND
GND
6 Bei nderung sind gleichzeitig
GND
7
8
GND
die Steuerungsmerkmale in
9 " &1 '
881.0010-00 sx entsprechend
10
GND zu erhhen.
11 " &1 '
12
GND
Protel
13 Erstm.Verw.
14
Mae ohne Leiterplatte: XMF664-C
Toleranzangabe
&"0"&,. GND LTG082

Datum Name
Benennung
Bearb. 10.10.02 Adamscheck
A
Gepr. 10.10.02 Bressel Rechnerplatte
Norm.
Stromlaufplan
Zeichnungsnummer: 881.0010-00 Blatt
1
02
01
144 A 03
--
11.04.03
10.10.02
Bud
AD.
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8 7 6 5 Verteiler Zust. nderung Datum Name Datei: P:\PROJEKT\Ht200S\ZBA568protel\Zba568a.DDB - ZBA71921.sch


ZBA719
4 3 2 1

E
Pt1 Pt2

P6 P5

1
2

1
2
C8 C9
4N7 4N7

D P1
14
13
GND-A GND-A 12
Temp2 11
10
Temp1 9
8
H2 MOC3061 7
R4 6 1 6
VCC 5
360R R10
V2
2 Heat1 4
4 220R Heat2 3
TIC225
2
R1 1
P2 360R
2
weder vervielfltigt noch Dritten zugnglich gemacht werden.
Und sie darf durch den Empfnger oder Dritten auch nicht in

Pwr-H1
HEATER 1 H1 MOC3061
C
Ohne unsere vorherige Zustimmung darf diese Unterlage

I R2 6 1
F2 VCC
T3,15A 360R R6
V1
2
4
anderer Weise mibruchlich verwertet werden.

TIC225 220R
C5
R3
P3 360R 2n2 L2
D3
2 Pwr-H2 Pwr+ 1 5 VCC
HEATER 1 C6 2 6 Ferrit-Perle
1N5819 C3
II
F3 D2
T3,15A
2n2 1N4937 3 7 C4 330
R9 Pwr-sw 4 8 330 GND-D
4

D1 100k
Pwr1

Pwr2

D4
B250C800 C2 L3 R8
D 5

10 3V9 150R
1 3
EN/UV 4 EN/UV
BP 1
3

1
U

I4 I1
S
S
S
S

B Pwr-F
03 TNY264 C7 SFH610
2

2
3
7
8

R11 C10 R5 Pwr-Bezug 01


4

275V 033 8R2 2

P4
(PE verbunden mit GND)
3
MAINS
2
1
F1 M.001 M.002
T6,3A GND Befest.bohr. Befest.bohr.
GND

Bei nderung sind gleichzeitig


die Steuerungsmerkmale in
881.1010-00 sx entsprechend
zu erhhen. 03

Protel
Erstm.Verw. Leiterplatte: XMF665-D
Mae ohne
Toleranzangabe
LTG082

Datum Name
Benennung
Bearb. 07.10.02 Budemann

Gepr. 07.10.02 Bressel Netzteilplatte


Norm. Stromlaufplan
03 242 A 03 25.03.03 Bud
Zeichnungsnummer: 881.1010-00 Blatt
1
02
01
112 A 03
--
20.03.03
07.10.02
Bud
Bud
Error : Lange.jpg file not found. ZBA720 v. 1 Bl.

Verteiler Zust. nderung Datum Name Datei: P:\PROJEKT\Ht200S\ZBA568protel\Zba568a.DDB - ZBA720-03.sch


ZBA720
4 3 2 1

E
Pt2

P5

1
2
C9
4N7

D P1
14
13
GND-A GND-A 12
Temp2 11
10
Temp1 9
8
7
6
5
4
Heat2 3
2
1
weder vervielfltigt noch Dritten zugnglich gemacht werden.
Und sie darf durch den Empfnger oder Dritten auch nicht in

H1 MOC3061
C
Ohne unsere vorherige Zustimmung darf diese Unterlage

R2 6 1 VCC
360R R6
V1
2
4
anderer Weise mibruchlich verwertet werden.

TIC225 220R
C5
R3
P3 360R 2n2 L2
D3
2 Pwr-H2 Pwr+ 1 5 VCC
HEATER 1 C6 2 6 Ferrit-Perle
1N5819 C3
F3 D2
T3,15A
2n2 1N4937 3 7 C4 330
R9 Pwr-sw 4 8 330 GND-D
4

D1 100k
Pwr1

Pwr2

D4
B250C800 C2 L3 R8
D 5

10 3V9 150R
1 3
EN/UV 4 EN/UV
BP 1
3

1
U

I4 I1
S
S
S
S

B Pwr-F
03 TNY264 C7 SFH610
2

2
3
7
8

R11 C10 R5 Pwr-Bezug 01


4

275V 033 8R2 2

P4
(PE verbunden mit GND)
3
MAINS
2
1
F1 M.001 M.002
T3,15A GND Befest.bohr. Befest.bohr.
GND

Bei nderung sind gleichzeitig


die Steuerungsmerkmale in
881.1080-00 sx entsprechend
zu erhhen. 03

Protel
Erstm.Verw. Leiterplatte: XMF665-D
Mae ohne
Toleranzangabe
LTG082

Datum Name
Benennung
Bearb. 14.10.02 Budemann

Gepr. 14.10.02 Bressel Netzteilplatte


Norm. Stromlaufplan
03 242 A 03 25.03.03 Bud
Zeichnungsnummer: 881.1080-00 Blatt
1
02
01
112 A 03
--
20.03.03
14.10.02
Bud
Bud
Error : Lange.jpg file not found. ZBA724 v. 1 Bl.

Verteiler Zust. nderung Datum Name Datei: P:\PROJEKT\Ht200S\ZBA568protel\Zba568a.DDB - ZBA724-03.sch


ZBA724