Service S1-S5 Engl

Steam Generator
1. Photograph of the Steam Generator in the S2 - S4 units
Clusure valve Warm-up valve
Excessive pressure valve
Steam valve
Level sensor
Steam equilibration vessel
Temperature switch for

warm-up valve
Boiler
PE connector
Heating element
behr Labor - Technik GmbH

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Service manual S2 - S4
erstellt am: Name:
11.08.04 D.Drewenskus Zchn. Nr.: 312-740-01 E Seite 1
Steam Generator
2. General Description of the Steam Generator
After the steam distillation apparatus is switched on, the water level in the steam generator is measured by
means of a level senosr. If the level lies below the required level, the pump delivering distilled water to the
steam generator is turned on and the steam generator (boiler) is filled. Once the water level reaches the
required level, the pump is switched off. Depending on the level of water in the steam generator, the filling
procedure can last for several seconds.
In the instances of an initial filling or a refilling after a repair, this filling process can take as long as two minutes.
After the required water level has been reached, the heating in the steam generator is started with full power.
During the warm-up phase, a warm-up valve, controlled by a temperature switch, is opened.
See diagram 312-749-06
Once the insulated outer wall of the steam generator reaches 92°C, as measured by the senor of the
temperature switch, the contacts of the switch open causing the warm-up valve to shut. Only once this valve
closes is it possible for the required steam pressure to build up. Once the pressure builds up to 0.3 bar, the
upper pressure limit, the heating is switched off. Now the apparatus is operationally ready and enters a
readiness state with controlled regulated heating.
After a distillation is started, the steam generator heats at a power level which has been entered and strored in
the distillation program. Power levels between 40 and 100% may be chosen. The steam thus produced is led,
through a pinch valve, a closure valve, the PP connectorand the steam introduction tube , into the sample vessel.
In the course of the distillation, the water level in the steam generator sinks. This is detected by the level sensor
and communicated to the electronics, which switches the steam generator water pump on.
Distillation is impossible if the cooling water supply is interrupted or if no sample vessel is

inserted into the apparatus.
After the steam distillation unit is switched off, a partial vacuum is created in the steam generator
by the condensation of the steam which causes the ventillation valve to open. The partial vacuum
is thus eliminated. When the steam generator heats up again, this ventillation valve closes again.
Ventillation valve
Level sensor with Water delivery tube

electronics
Steam hose Tube to pressure gauge and to

the warm-up valve

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Service Manual S2 - S4
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Steam Generator
Note:
If the water fed into the steam generator is not particularly clean or if there is dirt in the water storage
container, then the following problem can occur. After a few distillations, the error message “steam
generator heating” will be displayed and the execution of the distillation program will be halted. After a
few distillations, the error message “steam generator H2O on” will be displayed and the execution of
the distillation program will be halted.
Explanation:
If the steam generator is contaminated with dirt, then the boiling water will form foam on above the water
surface. This foam is sufficiently conductive in order to deceive the level sensor into determining that the
water level is filled up to the sensor level. As a consequence, no water will be refilled into the generator.
Only after the level falls further or the foam collapses will the sensor respond properly and refill the
generator. The large volume of cold water then refilled into the generator results in a drop in the
pressure in the steam generator. If the pressure drops below 0.03 bar then the error message “steam
generator heating” will be displayed and the distillation program will be stopped. Subsequently, the
steam generator will be heated at maximum heating power. When the pressure reaches 0.3 bar, the
distillation program, which was interrupted, will be resumed, using the same program data which had
already been entered.
If the pump delivering distilled water to the steam generator is unable to fill the generator to the sensor
level with water within 15 seconds after collapse of the foam layer, then the error message “steam
generator H2O on” will be displayed. The distillation will also be halted. If an attempt to manually fill the
steam generator is not successful, then the root of the problem lies elsewhere and the apparatus should
be switched off.
This above behavior is not indicative of a defect in the steam distillation apparatus, but rather the normal
reaction of the unit to undesired foam formation. If this behavior occurs frequently, then the water supply
container and the steam generator should be cleaned. It often suffices to empty and refill the steam
generator (See 312-742-01 to 03).

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Steam valve
Water for condenser cooling

In Out
2-way-valve (NC)
Closure valvel
Steam pressure
buffer vessel
Connection
Steam generator
air-vent valve
2-way-valve (NC)
Warm-up
valve
Distillation condenser
Distillation head Pressure sensor
T piece
Polypropylene connection
mainfold
Steam inlet
Controller circuit
Vent valvel Temperature switch board
Steam generator
Connection
Anti-backflow Anti-backflow Anti-backflow Anti-backflow

valvel valvel valvel valvel
Brown: Sample waste path
Distillate Blue: Venting
Orange: Lines under pressure during the readineess

state
Sample vessel
Boric acid addition pump Sodium hydroxide addition pump Peristaltic pump for Pump for delivering distilled
draining sample waste water to steam generator
Pump for addition of dilution water

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Functional Flow Diagram of the S4
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Steam valve

In Out
2-way-valve (NC)
Closure valvel
Steam pressure
buffer vessel
Connection
Steam generator
air-vent valve
2-way-valve (NC)
Warm-up
valve
T piece
mainfold
Steam inlet
Controller circuit
Steam generator
Connection

Orange: Steam path during destillation
Distillate Violett: Distillate
Sample vessel

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Steam valve

In Out
2-way-valve (NC)
Closure valvel
Steam pressure
buffer vessel
Connection
Steam generator
air-vent valve
2-way-valve (NC)
Warm-up
valve
T piece
mainfold
Steam inlet
Controller circuit
Steam generator
Connection

Blue: Venting before and after distillation
Distillate Green: Pressure above the temperature switching

point > 92°C
Sample vessel

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Steam valve

In Out
2-way-valve (NC)
Closure valvel
Steam pressure
buffer vessel
Connection
Steam generator
air-vent valve
2-way-valve (NC)
Warm-up
valve
T piece
mainfold
Steam inlet
Controller circuit
Steam generator
Connection

Distillate Red: Pressure up to the temperature switching

point at 92°C
Sample vessel

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16.08.04 D.Drewenskus Zchn. Nr.: 312-749-06 Seite 1
Steam Generator
4.6 Checking the Sample Vessel Clamp Safety Switch
Insure that there is NO sample vessel inserted into the sample vessel holding clamp. Then start a distillation.
An error message “Sampl Vessel“ appears. Close the error message display by pressing the start button.
The Start-Menu reappears.
4.7 Checking the Pressure Switch in the Condenser Cooling Water Line
Close the spigot of the line providing tap water for condenser cooling. Then start a distillation.
An error message “Cooling Water” appears on the display. Additionally, two sub-menus, “further” and “back”
appear.
If you have opened the tap on the cooling water in the meantime, confirm with “further” and the distillation
will proceed.
If, for example, there is a problem in the cooling water supply, mark “back” and enter to return to the
start-menu.
Once the problem has been remedied, you can start the distillation again.
This concludes the checks of all of the safety features.

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4.2 Checking the Level Sensor
You can check the level sensor in the service mode, which has already been discussed.
4.3 Checking the Pressure Sensor
You can also check the pressure sensor in the service mode.
It is possible to connect an external pressure indicator in the tubing leading to the sensor, which will enable
the value of the sensor to be checked. The sensor requires no maintenance. If it becomes defective, it wil
be necessary to replace the complete micro-controller circuit board.
4.4 Checking the Excess-Pressure-Safety Valve
The excess-pressure-safety-valve is factory set at 0.5 bar. At this pressure, the valve opens and the
pressure is released to the surroundings. Adjustment of the valve can only be done by the manufacturer,
but the user does have the capability to verify the proper operation of the valve.
Perform these operations with the greatest of care!
Connect an external pressure indicator in the silicone tubing leading to the pressure sensor. Let the
apparatus heat up. Use a screw clamp or pinch clamp behind the external pressure indicator to close the
tubing leading to the sensor. The micro-controller now recieves a signal of too low pressure from the sensor
and as a consequence, the the heating elements switched on, since the controller perceives that the
generator pressure is too low. Observe the external pressure indicator. The pressure rises very quickly.
Between approximately 0.5 to 06. bar the excess-pressure-valve should open and release the pressure
through the exit port.
If this does not occur, turn the power immediately off!
Replace the valve!
In the course of this test, the steam generator will reach a temperature above 110°C. The steam released
can cause serious burn injury. Be certain to keep a sufficient distance from the exit port of the
excess-pressure-valve!
If the test proceeded successfully, then turn the apparatus off, let it cool and then reassemble in the original
configuration.
4.5 Checking the Excess-Temperature-Shutoff-Switch
The switch is permanently set by the manufacturer. You cannot verify this setting. At a temperature > 147°C,
the power to the heating element will be shut off. After correcting the cause of the excessive temperature,
the switch is reset with the red pin. If the sensor capillary breaks, then
the switch will shut off the power. The capillary must then necessarily
be replaced.

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Steam Generator
4. Checking the Safety Features
4.1 General
Several components can be checked on the display in the service mode.

To do this, turn the apparatus on. An intorduction display appears for about
5 seconds. During this interval, turn the control knob clockwise. Then the
service display will appear.
The service mode only functions in the English language!
The display shown to the right will appear.

The frequency signal of provided by the level sensor is given in kHz.
If the frequency is below 20 kHz, then the generator is filled. If it is above
20 kHz, then the distilled water pump must provide water to the steam
generator. In the example picture, the signal is 1.8 kHz, which indicates that
the generator is filled.
Turn the control knob again in the clockwise direction. If the pump delivers
water to the generator, wait until the filling is completed before turning the
knob.
The display shown to the right will appear.

A value will be indicated on the new “heating” line now shown. This is the
pressure at the moment in the steam generator. In the illustrative example
shown, the pressure is exactly 0.282 bar.
This operating mode indicates that the steam generator is heating. If the
apparatus is cold, it will take some time until the pressure rises. Once the
pressure reaches 0.3 bar, the heating will be switched off. If the pressure
sinks below 0.2 bar, the heating will be switched on again. The switching of
the heating power is activated by pressure measurement within the range
0.2 to 0.3 bar. The apparatus is thus maintained in an operatiionally ready
status.
Turn the control knob again in a clockwise direction to obtain the display
shown at the right.
You can now select all options which are normally possible in normal
operaton, with three exceptions:
a)Only the English language can be chosen
b)Additional information on the pressure and fill status of the genreator will
be provided during the distillation
c)An additional sub-menu “SERVICE” appears in the menu entry
“OPTIONS”. This menu enables times and switching points to be altered.
In this example, the apparatus will continue to distill for another six seconds.
The momentary pressure is 0.232 bar and the fill-status is “full.”
The frequency range of the fill-status indicator can lie between 0.4 and
3,000.0. Values above 20 result in activation of the pump for delivery of
distilled water to the steam generator.

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Steam Generator
3.1 Level Sensor with associated Electronics
The sensor monitors the water level within the steam generator and sends a frequency signal to the
micro-controller. The level sensor operates in conjunction with the grounded boiler vessel as a frequency-
determining resistance, which varies as a function of the fill level. Changes in the level of the water result
in alteration of the frequency sent to the micro-controller.
3.2 Excess-Pressure-Safety-Valve
This valve insures that even in the event that the electronics become totally inoperative, no
excessive pressure can build up. If the pressure rises above 0.5 bar, the valve opens
mechanically and thus prevents a further increase in pressure.
If the excess-pressure-safety-valve activates, then there is a serious malfunction in the apparatus
and it should be switched off.
3.3 Excess-Temperature-Safety-Switch
A failure of the level sensor or the pump supplying the steam generator with distilled water could
result in insufficient water in the steam generator. As a consequence, the heating element in the
steam generator can overheat and burn out. The temperature probe of the temperature safety
shutoff circuit is mounted close to the heating element and is thus able to conduct the excessive
radiant energy, by means of a capillary, to the safety shutoff switch. The safety shutoff activates
at a temperature of 147°C and shuts off the electrical power to the heating element.
Following identification and repair of the situation causing the excess temperature, the excess-
temperature.safety-switch can be reset to the operating position by pressing the red button. Then
the next distillation can be started.
3.4 Pressure Sensor on the Controller Circuit Board
The pressure sensor is soldered directly onto the controller circuit board. Its lower tubing
connection leads via a silicone tube to the steam generator. This sensor provides the most
important information for controlling steam generation in the distillation apparatus.
At a pressure of 0.45 bar the sensor activates the display of Error Message No. 20, “Steam
Generator Pressure” and shuts off the power to the heating element.
3.5 Sample Vessel Safety Switch
If no sample vessel is inserted into the sample vessel clamp, this switch prevents starting a
distillation. Likewise, if the sample vessel breaks during a distillation, this switch will stop the
distillation.
3.6 Condenser Cooling Water Pressure Sensor
If there is insufficient water pressure (< 0.5 bar) at the inlet for tap water, a pressure sensor will
prevent starting a distillation or will shut down a distillation in progress.

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Steam Generator
3. Safety Features in the Steam Generator
Excess-pressure-
valve Excessive-temperature-
shutof-switch
Level sensor with

electronics
Upper connection
Sensor for the

exccessive temperature
shutof switch
Pressure sensor on the
micro-controller circuit board
Switch activated by insertion of

sample vessel into vessel clamp
Pressure
switch
Water inlet valvel

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Steam valve

In Out
2-way-valve (NC)
Closure valvel
Steam pressure
buffer vessel
Connection
Steam generator
air-vent valve
2-way-valve (NC)
Warm-up
valve
T piece
mainfold
Steam inlet
Controller circuit
Steam generator
Connection

Distillate Green: Lines under pressure during the readineess

state
Red: Delivery of boric acid
Sample vessel
Yellow: Delivery of sodium hydroxide
Boric acid addition pump Sodium hydroxide addition pump Peristaltic pump for
draining sample waste
Pump for delivering distilled Violett: Delivery of dilution water
water to steam generator

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Steam Generator S1
1. Photograph of the S1 Steam Generator
Pressure sensing switch

for regulation heating element
Safety pressure switch
Warm-up valve
Steam valve Overpressure valve
Level sensor
Polypropylene
connector
Steam pressure
buffer vessel
Temperature switch
for warm-up valve
PE-Connector
Boiler
Heating element

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Service manual S1
erstellt am: Name:
24.08.04 D.Drewenskus Zchn. Nr.: 312-740-10 E Page 1
Steam Generator S1
2. General Description of the Steam Generator
After switching the steam distillation apparatus on, the water level in the steam generator is determined by
means of a level sensor. If the water level lies below the required value a distilled water delivery pump is
activated and water is filled into the steam generator. When the water level reaches the required value, the
pump shuts off. Depending on the level of water in the steam generator, the filling procedure can last
several seconds.
In the instance of a first filling or a refilling after a repair, the filling procedure can last up to two minutes.
The S1 starts heating immediately after being switched on. If the steam generator was completely empty
of water, this could, under some circumstances, lead to the destruction of the heating element. In the case
of a first filling, always remove the plug 13 from its socket. Then, when the steam generator is filled, turn
the apparatus off and reinsert the plug into its socket. Switch the apparatus on again and allow the steam
generator to heat up.
During the warm-up phase, a warm-up valve is activated by means of a temperature switch.
See Fig. 312-749-11, page 1
Once the insulated outer wall of the steam generator reaches 92°C on a temperature switch, this activates
and the warm-up valve closes. Only then can the required steam pressure build up in the steam generator.
Once this pressure reaches 0.2 bar, the heating is shut off. Then the apparatus is ready for operation. In
use, the apparatus switches the heating on and off at pressures of 0.16 and 0.2 bar respectively.
See Fig. 312-749-11, page 2
After the start of a distillation, the steam proceeds through the “steam” pinch valve, through the steam
equilibrating vessel, through the polypropylene connector and the steam introduction tube, into the sample
vessel.
See Fig. 312-749-11, page 3
During course of the distillation, the water level in the steam generator sinks. This is detected by the level
sensor and communicated to the electronics, which then responds by turning the pump delivering distilled
water to the steam generator on.
A distillation is not possible if the flow of condenser cooling water is interrupted or if no sample vessel is
inserted into the distillation unit.
The level sensor in the S1 is a conductivity module. Steam distillation units S2 S5 employ a different type
of sensor. The sensor electronics is found on the circuit board.
After the end of the distillation, a valve shuts off the flow of steam and the sample vessel is opened to the
atmosphere by a vent arm in the same valve. An anti-backflow valve in the distillation head prevents the
distillate from being sucked back into the sample vessel.
See Fig. 312-749-11, page 4
After turning the steam distillation apparatus off, the cooling and condensation of the steam in the steam
generator results in a partial vacuum. This causes the ventilation valve to open to the atmosphere, thus
eliminating the partial vacuum. This valve closes again when the steam generator is again heated.
See photographs on page 3.

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Service manual S1
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Steam Generator S1
3. Connection to the Steam Generator
Ventilation valve
Steam outlett
Excessive pressure
release valvel
Pressure
measurement
Level sensor
Water supply line

to steam generator
4. Safety features
Excessive pressure
release valve
Excessive temperature
shutoff switch
Excessive pressure
shutoff switch
Sensor connection of
excess temperatur
shutoff switch

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Service manual S1
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Dampferzeuger S1
Pressure
switch
Switch activated by insertion
of samlpe vessel into vessel clamp
Water inlet valve
Containers for both H2O and NaOH are included in the contents of delivery. The level sensors built into
these containers are active components in the performance of various functions and in the safety checks.
4.1 Excessive pressure release valve
In the event that the electronics become totally inoperative, this valve insures that no excessive pressure
can arise in the steam system. If the pressure rises above 0.5 bar, this valve opens mechanically and thus
prevents a further increase of pressure.
If this occurs, there is a major failure in the distillation unit and it should be shut off immediately.
4.2 Excessive temperature shutoff switch
If there is a failure in the level sensing system or in the steam generator water pump not enough water will
be provided to the steam generator. This causes the heating element in the steam generator to overheat
and it may possibly be destroyed. The sensor connected to the excess temperature safety shutoff switch
is mounted close to the heating element. At excessive temperatures, a liquid contained in the sensor
expands, transmitting a pressure signal via a capillary to the safety switch. The safety switch is set to
activate at a temperature of 147°C, at which point it shuts off power to the heating element.
After identification of the problem and repair, the excess temperature safety switch can be reset by
pressing the red button. Then the next distillation can be started.
4.3 Safety backup pressure cut-off switch
In the event that the normal heating controller, which cycles between 0.16 and 0.2 bar, fails, a backup
pressure safety switch, with a shutoff at nominally 0.3 bar (0.26 0.34 bar) engages. It is thus possible to
recognize a defective heating controller by an increased level of steam production.
4.4 Switch in the vessel holding clamp
If no sample vessel is inserted into the vessel holding clamp, it is not possible to start a distillation. A switch
in the vessel holding clamp senses the absence of the sample vessel and prevents the start of the
distillation. Likewise, if the sample vessel breaks in the course of the distillation, then the distillation will be
interrupted.
4.5 Pressure switch in the condenser water supply line.
If the inlet tap water pressure at the entrance to the water valve is insufficient (at least 0.5 bar), then safety
switch will prevent start of a distillation or interrupt a distillation in progress.

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Service manual S1
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Steam Generator S1
5. Checking the Safety Features
5.1 Checking the excessive pressure valve
The excessive pressure valve is factory-set at 0.5 bar. Above this pressure, the valve opens, releasing the
pressure to the atmosphere.
This valve can only be adjusted by the manufacturer, but the user External pressure
may verify its proper functioning. gauge
In performing this check, the greatest of caution must be Steam outlet

exercised!
Connect an external pressure guage into the silicone tubing line

leading to the pressure sensor. Allow the apparatus to warm up
to the “ready” state. Use a pinch clamp to close off the tubing
leading to the sensor (after the branch to the external pressure
gauge). Let the apparatus warm up. The electronics now receives
no signal from the pressure sensor and consequently the heating
Hose to external pressure gauge
will not be switched off. Watch the external pressure gauge. At a
pressure between 0.5 and 0.6 bar, the excessive pressure valve
will open and the pressure will be released to the atmosphere.
If this does not happen, switch the distillation unit off immediately! Clamp here
In this case, replace the valve! Hose to pressure controller
In this test, the steam generator will be heated to more than

110°C. The escaping steam can cause serious injury. Therefore, stay sufficiently far away from the vent
port of the excessive pressure safety valve!
If the check was successful, switch the apparatus off, allow it to cool and reconnect the tubing in the
original configuration.
5.2 Checking the pressure switch
The pressure switch is factory set at the pressures previously stated. Nevertehless, you have the possibility
to check operation at these switching points.
To do this, insert an external pressure guage into the pressure sensor tubing, as described above. Let the
apparatus warm up to the “ready” state. The pressure on the manometer should now fluctuate between
0.16 and 0.22 bar.
Switch the apparatus off and disconnect plug 17. Connect instead a short-circuit plug. This simulates a
defective pressure activated heating control switch. Switch the apparatus on again. The pressure now rises
to 0.33 bar and then fluctuates between 0.27 and 0.33 bar. This completes the check and you can now
reconnect the apparatus in its original configuration.
5.3 Checking the excessive temperature safety shutoff switch
The switch is permanently adjusted by the manufacturer, but you have the capabillitiy to check its operation.
It shuts off the 230 VAC power to the heating element at a temperature > 147°C. After repairing a defect,
which caused the switch to activate, it can be reset by means of the red pin. The switch shuts off in event
of a breakage of the capillary tube to the sensor. In this case, the switch (including temperature
sensor / capillaty tube) must be replaced.

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Steam Generator S1
5.4 Checking the safety switch in the sample vessel holding clamp
Start a distillation with no sample vessel in the sample vessel holding clamp.
The distillation does not start and no NaOH is dispensed.
5.5 Checking the pressure sensor in the cooling water inlet
Start a distillation. Then turn off the water tap providing cooling water to the apparatus.
The distillation will be stopped, but delivery of NaOH will still function.
5.6 Checking the H2O float switch in the distilled water container
Unplug the H2O level sensor cable from the back of the apparatus. The red LED on the front panel
illuminates. It is not possible to start a distillation. The steam generator heating is shut off.
5.7 Checking the NaOH float switch in the NaOH container
Unplug the NaOH level sensor cable from the back of the apparatus. Pressing the button for delivering
NaOH brings no reaction NaOH and the LED remains off.
This concludes the check of all safety functions of the S1.

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Steam valve
Cooling water
In Out
2-Way valve (NC)
Steam pressure Solenoid valve pressure control for S1

buffer vessel
Connector
Pressure Safety
Ventilation Warm-up control switch pressure switch
valve valve
Distillation head >O,2 >O,3
T-Connector
PP-Connector
Steam inlet
Ventilation vent Temperature switch
Steam generator
Anti-backflow Anti-backflow
valve valve
Distillate Red: Pressure up to the 92°C temperature

switching point
Sample vessel
NaOH pump Water pump for steam generator

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Functional Schematic of the S1
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Steam valve
Cooling water
In Out
2-Way valve (NC)

buffer vessel
Connector
Pressure Safety
valve valve
T-Connector
PP-Connector
Steam inlet
Steam generator
valve valve
Distillate Green: Pressure above the 92°C temperature

switching point
Sample vessel

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Steam valve
Cooling water
In Out
2-Way valve (NC)

buffer vessel
Connector
Pressure Safety
valve valve
T-Connector
PP-Connector
Steam inlet
Steam generator
valve valve
Orange: Steam pathway during distillation
Distillate Violett: Distillate
Sample vessel

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Steam valve
Cooling water
In Out
2-Way valve (NC)

buffer vessel
Connector
Pressure Safety
valve valve
T-Connector
PP-Connector
Steam inlet
Steam generator
valve valve
Distillate Green: Pressure in state of operational readiness
Yellow: Addition of NaOH
Sample vessel

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Symptoms of Malfunctions
1. The drainage pump does not pump the waste.
a.)The pump tube in the pump is defective.
Remove the electrical power plug and dismount both back

panels.
Locking fastener
The pump need not be dismounted and removed!
Turn the locking fastener of the peristaltic pump clockwise.
This will release the pump tube.
Remove the pump tube segment and replace it with a

segment of Novoprene tubing (4.8 x 1-6 mm) of 120 mm
length.
Squeeze the hose clamps together with a pliers and pull the
tubing off the nipples.
Push the hose clamps over the new tubing segment. Connect
the tubing segment to the nipples and secure it with the hose
Hose clamps
clamps. Pay attention to the orientation of the grip protrusions
of the hose clamps! These must point inwards. Then
reassemble the pump.
Flat side
Grip protrusion

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Symptoms of Malfunctions
b.) The screw-on connection to the polypropylene

connection is not tight.
Tignten the fastening nut.

Adjust the position of the tubing or replace the tubing.
Fastening nut
c.) The sample draining tube of the pump, which

provides dilution water to the sample is disconnected.
If the suction tube from the sample dilution water pump

is disconnected, the pump cannot develop a vacuum,
since both tubes are connected by the polypropylene
connection. If there is no column of water in the tube
leading from the water container, located beneath the
desktop, then the drain pump will simply suck air in
through the water line. No vacuum can be developed
et
tl
and the sample waste will not be pumped out.
Ou
H2O tubing

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Maintenance
1. Empty the Steam Generator

Unplug the electrical power cable from the mains socket!
Pull plugs 16 and 8 out of the socket strip.
Plug 16
Heating/Excessive
temperature switch
Plug 8
Pump for steam
generator water
Remove the vacuum tubing from the drain pump
Cut two tubing segments as follows:
Silicone tubing: 3 mm ID, 6 mm AD, 50 mm length

Teflon tubing: 2 mm ID, 4 mm OD, 1000 mm length
Stick the end of the Teflon tube into the end of the
Silicone tube.
Stick the free end of the silicone tube onto the suction
nipple of the waste drain pump.

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Maintenance
Disconnect the steam tube from the steam valve.
Be careful! The steam generator must be cold and under no
pressure.
Push the Teflon tube into the silicone tubing, which was
removed until it reaches the bottom of the steam generator.
It may be helpful to make a mark on the Teflon tube at this
point.
Insert the electrical mains plug into a mains socket and switch the apparatus on. Go immediately to the
Service Mode Manual Entry by turning the control knob about ½ revolution while observing the status
display. Once in the Service Mode, turn the control knob to Options > Manual Entry > Drain Sample.
With Drain Sample highlighted, press the button. The sample waste pump starts. Hold the button depressed
until the steam generator is empty.
Next, switcht the apparatus off and restore the apparatus to its original configuration.
The refilling of the steam generator will be described next.

Düsseldorf
erstellt am: Name:
Maintenance
2. Refilling the Steam Generator
Add some distilled water to a 1 liter flask. Dissolve some (the

tip of a spoonfull) common cooking salt (NaCl) in the water.
Then fill the flask to the mark with distilled water.
Insert the end of the water supply tube from the pump
providing distilled water to the steam generator into the flask
containing the salt water.
Switch the apparatus on. The pump draws up the salt water.
After approximately 700 ml, the steam generator has been
filled. If the pump continues to operate, then there is a defect
in the level sensor. In this case, switch the apparatus off.
If the pump switches off, then the heating of the steam

generator will begin. Thereafter, the apparatus is ready for
operation.
Insert the end of the water supply tube back into the
container of distilled water.

Düsseldorf
erstellt am: Name:
Steam valve

In Out
2-way-valve (NC)
Closure valvel
Steam pressure
buffer vessel
Connection
Steam generator
air-vent valve
2-way-valve (NC)
Warm-up
valve
T piece
mainfold
Steam inlet
Controller circuit
Steam generator
Connection

Distillate
Sample vessel

Düsseldorf
Hose and Tubing Connection of the S4
erstellt am: Name:
Steam valve
Cooling water
In Out
2-Way valve (NC)

buffer vessel
Connector
Pressure Safety
valve valve
T-Connector
PP-Connector
Steam inlet
Steam generator
valve valve
Distillate
Sample vessel

Düsseldorf
erstellt am: Name:
Steam valve

In Out
2-way-valve (NC)
Steam pressure
buffer vessel
Connection
Steam generator
air-vent valve
Warm-up
valve
T piece
Steam inlet
Controller circuit
mainfold
Steam generator
valvel valvel
Distillate
Sample vessel
Sodium hydroxide addition pump Pump for delivering distilled


Düsseldorf
erstellt am: Name:
Steam valve

In Out
2-way-valve (NC)
Closure valvel
Steam pressure
buffer vessel
Connection
Steam generator
air-vent valve
2-way-valve (NC)
Warm-up
valve
T piece
mainfold
Steam inlet
Controller circuit
Steam generator
Connection
Anti-backflow Anti-backflow Anti-backflow

valvel valvel valvel
Distillate
Sample vessel
Sodium hydroxide addition pump Peristaltic pump for Pump for delivering distilled

Düsseldorf
erstellt am: Name:
Steam valve

In Out
2-way-valve (NC)
Steam pressure
buffer vessel
Connection
Steam generator
air-vent valve
Warm-up
valve
T piece
Closing cap Steam inlet
Controller circuit
mainfold
Steam generator
Anti-backflow
valvel
Distillate
Depending on configuration max be providet
with adapter connection to pycnometer.
Sample vessel
Pump for delivering distilled


Düsseldorf
Hose and Tubing Connection of the S2A
erstellt am: Name:
Keyboard circuit board
Level sensor
Withe
Withe
10 pole ribbon cable

1
4
Steam generator
Solid state
relais Heating
3
2
Pressure controller
0,2 bar
18 P
1 3
17 2
S1 master circuit board

16 P
1 3
15 2
1
Excessive pressure
Level NaOH
14 0,3 bar
Level H2O
13
2
11 12
3 4 5 6 7 8 9 10
1 4 2 4
Cooling water
t°C
Sample vessel
Warm-up
valve
1 3 1 3 M M
White =
Cooling water valve

White
Steam valve
NaOH
steam generator
Water pump for
White White
Switching power supply +

24V
-
N
L
Material Maßstab
behr Labor-Technik GmbH
Spangerstraße 8
Power supply
slide-in insert S1
21 22(i)
40599 Düsseldorf
0211 / 74 847 -0
S1
Datum Name Wiring diagram
I>
11 12 Bearb. 10.08.04 D.Drewenskus

Gepr.
L PE N
Die Zeichnung ist Eigentum der behr

Power switch, 10 A
Socket for electrical power cable, Labor-Technik GmbH. Änderungen,
10 A with filter Vervielfältigungen sowie die Nutzung
(auch auszugsweise) bedürfen der
vorherigen Genehmigung.
Zeichnung-
Nummer : 312-201-02 E
Zust. Änderung Datum Name
Keyboard circuit board
Level sensor
Withe
Withe
10 pole ribbon cable

1
4
Steam generator
Solid state
relais Heating
3
2
Pressure controller
0,2 bar
18 P
1 3
17 2
S1 master circuit board

16 P
1 3
15 2
1
Excessive pressure
Level NaOH
14 0,3 bar
Level H2O
13
2
11 12
3 4 5 6 7 8 9 10
1 4 2 4
Cooling water
t°C
Sample vessel
Warm-up
valve
1 3 1 3 M M
White =
Cooling water valve

White
Steam valve
NaOH
steam generator
Water pump for
White White
Switching power supply +

24V
-
N
L
Material Maßstab
behr Labor-Technik GmbH
Spangerstraße 8
Power supply
slide-in insert S1
21 22(i)
40599 Düsseldorf
0211 / 74 847 -0
S1
Datum Name Wiring diagram
I>
11 12 Bearb. 10.08.04 D.Drewenskus

Gepr.
L PE N
Die Zeichnung ist Eigentum der behr

Power switch, 10 A
Socket for electrical power cable, Labor-Technik GmbH. Änderungen,
10 A with filter Vervielfältigungen sowie die Nutzung
(auch auszugsweise) bedürfen der
vorherigen Genehmigung.
Zeichnung-
Nummer : 312-201-02 E
Zust. Änderung Datum Name

Service S1-S5 Engl

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Steam Generator

1. Photograph of the Steam Generator in the S2 - S4 units

Clusure valve Warm-up valve

Excessive pressure valve

Steam equilibration vessel

Temperature switch for

behr Labor - Technik GmbH

2. General Description of the Steam Generator

See diagram 312-749-06

See diagram 312-749-07

See diagram 312-749-08

Distillation is impossible if the cooling water supply is interrupted or if no sample vessel is

Level sensor with Water delivery tube

Steam hose Tube to pressure gauge and to

behr Labor - Technik GmbH

behr Labor - Technik GmbH

Water for condenser cooling

Anti-backflow Anti-backflow Anti-backflow Anti-backflow

Brown: Sample waste path

Distillate Blue: Venting

Orange: Lines under pressure during the readineess

behr Labor - Technik GmbH

Water for condenser cooling

Anti-backflow Anti-backflow Anti-backflow Anti-backflow

Orange: Steam path during destillation

Distillate Violett: Distillate

behr Labor - Technik GmbH

Water for condenser cooling

Anti-backflow Anti-backflow Anti-backflow Anti-backflow

Blue: Venting before and after distillation

Distillate Green: Pressure above the temperature switching

behr Labor - Technik GmbH

Water for condenser cooling

Anti-backflow Anti-backflow Anti-backflow Anti-backflow

Blue: Venting before and after distillation

Distillate Red: Pressure up to the temperature switching

behr Labor - Technik GmbH

4.6 Checking the Sample Vessel Clamp Safety Switch

This concludes the checks of all of the safety features.

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4.2 Checking the Level Sensor

4.3 Checking the Pressure Sensor

4.4 Checking the Excess-Pressure-Safety Valve

Perform these operations with the greatest of care!

If this does not occur, turn the power immediately off!

Replace the valve!

4.5 Checking the Excess-Temperature-Shutoff-Switch

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4. Checking the Safety Features

Several components can be checked on the display in the service mode.

The display shown to the right will appear.

The display shown to the right will appear.

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3.1 Level Sensor with associated Electronics

3.4 Pressure Sensor on the Controller Circuit Board

3.5 Sample Vessel Safety Switch

3.6 Condenser Cooling Water Pressure Sensor

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3. Safety Features in the Steam Generator

Level sensor with

Sensor for the

Switch activated by insertion of