Automated Softening Point Tester. Model ASP-5. Maintenance Manual

Transcription

1 Automated Softening Point Tester Model ASP-5 Maintenance Manual Ver Read this manual thoroughly before using the product, and store in a safe place for future reference. TANAKA SCIENTIFIC LTD, TOKYO, JAPAN

2 Contents 1Setting Changes Heater Output Flow Constants Setting Screen Setting the temperature rise rate Setting the measuring range Setting the test conditions Setting the external connections Temperature Unit Selection and Temperature Correction Date and Time Setting Constants Printing I/O Check Adjustment Ring Holder Adjustment Faults and Countermeasures Fault Displays and Countermeasures Unit Faults and Countermeasures Parts Replacements Control Unit Parts Replacements 18 (1) Replacing the CPU 18 (2) Replacing the ROM 18 (3) Replacing the fluorescent display 19 (4) Replacing the power supply Measuring Unit Parts Replacements 20 (1) Replacing the projection lamp 20 (2) Replacing the light receiver board 20 (3) Replacing the heater 21 (4) Replacing the cooling fan 21 1

3 1. Changing Settings The switches on the front of the control unit can be used to change settings. While holding down the RESET key, press the FUNCTION key. Then release only the RESET key to display the menu shown in Fig.1. Select the necessary menu item by using the right/left keys to move the cursor, and press the FUNCTION key to confirm the selection. The screen in Fig. 2 is displayed when "Para set" is selected and the FUNCTION key pressed to confirm the selection. When the FUNCTION key is pressed after adjusting settings, the cursor automatically moves to "End". Keep pressing the FUNCTION key to return to the original screen. After returning to the main screen shown in Fig. 1, press the RESET key to return to the Menu screen. Be sure to record any changes to setting numeric values. This record will be needed when the battery for the RAM goes flat (about 5 to 7 years). Ver 1.0 Para set Temp cal Time set Para Prt Fig.1 Menu Screen Rate Range Test. para Output End Fig.2 Parameter Settings Screen 2

4 Rate Bath liquid, initial heating, base, limiter, auto start temperature, temperature rise rate, and PID settings Range Mode, bath liquid, one-sided test, safety stop temperature, and upper and lower measuring temperature limits Para set Test. para Detection rate, additional mode, and result rounding Output Connected equipment, equipment number, End test number, detailed printing, and sample name Water bath C/F Temperature correction in water bath Temp cal Glycerin bath C/F selection End Temperature correction in glycerin bath Time set Sets the internal clock (option) Para Prt Prints the settings (only applicable when a printer is connected) From the standard main screen, the following screens can be displayed by key operations: Test results This screen displays up to 20 test results. Press the RESET and MODE keys together, then release the RESET key first. I/O check This screen is used to check tester I/O. Press the RESET key together with the up key and down key and release the RESET key first. Fig. 3 Details of the Settings Screen 3

5 1.1 Heater Output Flow Start: The initial heat is calculated and output (base heater + initial heater). 1 min (water), 2 min (glycerin) later: The initial heater is turned off for the base heater and bias heater output. Auto start temperature: Auto control starts when the temperature rise rate has reached 5 C/min. Until then, the above heater output remains ON. Auto control start: The heater output is calculated from the PID constant. The heater output limit is calculated and the heater output (base heater + bias heater) is limited. Then the result is output. 1.2 Constant Setting Screen Heating settings For the two different kinds of bath liquid (water and glycerin), the following values can be set: Liquid Init BaseLimit Auto Water 15% 50% 00% 005 C Rise rate P I D 5.0 C/min End Fig.4Heating Settings Screen Liquid Set the bath liquid type (water or glycerin) used in the test. Init Heater output 1 min (water) or 2min (glycerin) after the start of a test. Base Heater output during a test. Limit Calculated output of the base and bias heaters in the setting range. Auto Temperature at which to start automatic heating control. Auto control starts if the heating rate exceeds the set value (5.0 C/min in the above example) at this or higher temperatures. Rise rate Temperature rise per minute (only 5.0 C/min preset) Except when the rate is 5.0 C/min, set the necessary items again. P,I,D Calculation parameters for auto heating rate adjustment. 4

6 1.2.2 Measuring range settings For two or four modes, the following items can be set: Mode Liquid 1-sample Cut temp 0 Water off 15 C Range_H Range_L 080 C 020 C End Fig.5Measuring Range Setting Screen Mode Selects the mode that is displayed on the ordinary main screen. The tester has two standard modes, water and glycerin. However, two additional modes can be added by setting "Add mode" in "Test parameters" to Yes. For example, tests that end with one-sided drop detection can be set as an additional mode. Liquid Specify the bath liquid for use in the mode (water or glycerin). When this is specified, tests are performed using the settings from the heating settings screen. 1-sample Usually set to off. When Yes is specified, testing ends after the detection of a one-sided drop. Cut temp Temperature of safety stop after one-side drop detection (Usually, +10 C) By default, a test ends about two minutes after one-side drop detection. Change the setting when measuring samples of very different softening points simultaneously. Range_H Usually set to 80 C for the water bath and 150 C for the glycerin bath. Range_L Usually set to 20 C for the water bath and 75 C for the glycerin bath Test parameter settings Drop conditions, test modes, and test result processing can be modified as follows: Det. sens Add.menu Rounding 85% Off On End Fig.6Heating Settings Screen 5

7 Det.sens The default is 85%. A drop is detected when the receiver input level has dropped to "Average detector input over preceding 10 to 20 seconds Detection sensitivity 100". During a test, check the status on the secondary display (press the CHECK key). (See Fig.7) Status Projector output Receiving Level (L-R) MEAS P_OUT RATE REC LEVEL 00% 0.0 C 50% 49% 00% 25.0 C 35% 34% H_OUT TEMP DET LEVEL Heater output Sample drop detection level Fig. 7 Sub Screen Secondary display Add.nenu Two additional test modes can be added to the original two test modes. To complete testing a sample, select On here and also at "1-sample" On the measuring range setting screen. In addition, the safety stop temperature can be changed. Rounding Usually set to On. Rounds the average test result to the nearest 0.5 C External connection settings Printer, PC, and other external connections can be set as follows: Ext.out Inst No. Test No. Computer Opt.prt Sample ID Off Off End Fig. 8External Out Settings Screen 6

8 Ext.out "Computer" in default. Select either "Printer" or "Computer" to specify the equipment connected to the RS-232C port. Inst No. Low-order two digits of the serial number of the Test unit. This can be used as an identification number for external connections. Test No. Counter from 0000 to 9999, incremented by one at the end of each test Opt.prt Usually set Off. If a printer is connected, this setting enables the heating rate and other data to be printed after a test. Sample ID Usually set Off. This setting enables sample name input for each test. The sample name can be added to the printer and test results. 7

9 1.3 Temperature Unit Selection and Temperature Correction The temperature correction screen is used to make any corrections if there are any differences between the temperature display and the softening point thermometer. The tester handles two kinds of bath liquid (water and glycerin). Compare the temperature sensor (displayed temperature) of the tester and the softening point thermometer while using the necessary bath liquid in advance to check the differences Procedure of Calibration Insert the thermometer suitable for the selected liquid bath into the specified hole in the ring stage and secure it with an elastic band or wire at the standard position. After checking that the temperature sensor is also at the specified position, place a beaker containing the bath liquid at the specified position of the measuring unit, put the ring holder in the beaker, and attach the beaker to the ring holder. Select the bath liquid using the MODE key and start a test. Compare and record the thermometer reading and temperature display every 10 C. (Copy the attached settings table for recording data during this operation.) Repeat the above operation twice and pigeonhole data as references for correction Select Bath Medium and Temperature Unit. Select Temp Cal from Menu screen, Fig 9 appears first. Select Water or Glycerin (blinks) then press FUNCTION key. Fig.10 appears by this operation. Push Right or Left key to blink C, and then change it by Up or Down key. If you want to go Temperature offset entering screen, select Next, if you want to finish, select End and then push FUNCTION key. Bath select Set temp unit End Water Glycerin End Fig.9Bath Liquid Selection Screen C Next Fig.10Bath Liquid Selection Screen Correct differences at each correction point, which are at every 20 C from 0 to 200 C on the following temperature correction screen for each bath liquid: Example Correction when the 40 C reading is 0.5 C lower than the thermometer reading In Fig. 10, the current temperature correction value for 40 C is 1.0 C and the necessary correction value is +0.5 C. New correction value=-1.0 C+0.5 C=-0.5 C -0.5 for 40 C 8

10 (Water) Next Temp Pos Offset End Addition to 40 C Bath liquid Addition to the total measuring temperature area Displayed temperature Correction points are interpolated linearly C 21.5 C 0.5 C 0 C 20 C 40 C Measured temperature Fig. 10 Temperature Correction (Water bath) To display the next correction screen, move the cursor using the right/left keys and press the FUNCTION key. When the cursor is at a correction value, pressing the FUNCTION key moves the cursor to the End position. Press the FUNCTION key again to return to the initial temperature correction screen. From this screen, press the RESET key to return to the standard main screen, or select End and press the FUNCTION key to return to the main settings screen. 9

11 1.4 Date and Time Settings (Optional) If a clock board is included with the unit, date and time are set prior to shipping. When necessary, the date and time can be adjusted as follows: FUNC key Set End Set Value 0212/1614: 39 Date Time 0212/1615: 3005 Fig.11Date and Time Settings Screen After moving the cursor to the position to be updated using the right/left keys, press the FUNCTION key to update the selected Date Time field. When finished, move the cursor to End and press the FUNCTION key to return to the previous screen, or press the RESET key to return to the standard main screen. 1.5 Printing Settings (Option) If an optional printer is connected, settings are printed. If an optional printer is not connected, nothing happens. (If a PC is connected and "Printer" is set on the external connection setting screen, the settings can be saved as a file using "Hyper terminal" or other communication software. ExampleBaud Rate 9600 bps(for optional printer) Parity Data bit Even 7 bits For the RS-232C connection cable and other details, refer to the Communication Interface (RS-232C) Manual. 10

12 2. I/O Check From the standard main screen, press the up key and down key and RESET key together, then release the RESET key to display the I/O check screen. Move the cursor to a setting using the right/left keys, change the setting to ON or OFF using the up/down keys, and check individual I/O equipment. Ex.: Heater output check Set RL (relay) to ON and also SSR to ON. If the output is normal, the heater monitor LED on the front of the measuring unit lights. After the check, be sure to set RL and SSR to OFF and press the RESET key to return to the standard main screen. OUT RL SSR FAN BZ LAMP Off Off Off Off On B0 IN Pos err Temp Photo L R Off Fig. 12 I/O Check Screen OUT RL Start relay Heater circuit safety relay. The heater SSR operates only when this relay is ON. SSR Heater SSR Solid state relay for heater output ON/OFF FAN Cooling fan Heater cooling fan BZ Optional external buzzer (Test end) Optional DC24V external buzzer LAMP Projection lamp for drop detection When the lamp is turned ON, the light quantity is automatically adjusted. 11

13 IN Pos err Optional Enabled when the sensor position detection function is added Temp Sensing temperature of temperature sensor Photo L R Left and right receiver input levels. When LAMP is set to ON, the input levels are automatically adjusted to about 50%. 3. Adjustment 3.1 Ring Stage Adjustment To avoid detection errors, inspect the position of the ring stage periodically. If mounting nuts are loose, check the mounting dimensions of the sample shelf and bottom plate. Adjust the dimensions shown in Fig. 13 and tighten the nuts. From the top of the ring holder to the lower face of the top plate : 100+/-0.1mm 100 From the lower face of the Ring holder to the upper face of the bottom plate: 30+/-0.1mm 30 Fig. 13Dimensions of the Ring Holder According to ASTM D36, the bottom of the shouldered rings in the ring holder shall be 25 mm above the upper surface of the bottom plate. ASP-5 is using photoelectric detection system. If the light beam is passed just above the bottom plate, reflected beam from the bottom plate disturb the correct detection. The axis of light beam of ASP-5 is passing 5 mm above the upper surface of the bottom plate. So, ASP-5 detects ball falls 25 mm below the bottom of the shouldered rings. 12

14 4. Faults and Countermeasures 4.1. Error Messages and Countermeasures TROUBLE TEMP SENSOR Temp[ C]410.8 Fig. 14 Temperature Sensor Fault Screen The temperature sensor (PT-100) has an open circuit. Replace the temperature sensor. (Replace the sensor at the three-pin connector on the upper left of the measuring unit.) TROUBLE PHOTO SENSOR LAMP Temp[ C] 24.9 Fig. 15 Projector Lamp Fault Screen Lamp output is not reaching either the right or left light detectors. Check that lamp output is normal and reaching the light detectors. When the START key is pressed, the intensity of light is automatically adjusted. If the lamp does not light, replace the lamp. TROUBLE PHOTO SENSOR RIGHT Temp[ C] 24.9 Fig. 16 Light Receiver (Right) Fault Screen The right light detector of the optical system is not correctly detecting light. When the START switch is pressed, the optical system is reported as being adjusted on the right side of the standard main screen. Check that level of light detected changes. If the intensity of light detected does not change, replace the light detector. 13

15 Light Receiver Light Receiver Cover Assembly Diode Array exposed to light Slit Fig. 17 Light Detector Check TROUBLE REPLACE BATTERY Temp[ C] 24.9 Fig. 18 Battery Running Out Screen The internal settings backup battery is running out. Replace the battery. TROUBLE SENSOR POSITION Temp[ C] 24.9 Fig. 19 Sensor Position Incorrect Screen Tests are stopped in about 10 minutes if started without the temperature sensor in place or if the heater has an open circuit. Check that the temperature sensor is in place, and that the heater is functioning. (To check heater output, check the heater current indicator lamp on the measuring unit after starting a test.) 14

16 TROUBLE S. P > 80.0 Temp.[ C] 80.2 Fig. 20 Softening Point Detection Failure Screen The above message is displayed if the sample does not drop within the measuring range. In this case, press the RESET key and then the FUNCTION key to check the measuring range on the sub screen. Circumstances that caused the test to end can be found on this display: Beyond the measuring range Absolute stop temperature (water bath: 90 C, glycerin bath: 200 C) 15

17 4.2. Unit Faults and Countermeasures Table 1Control Unit Troubleshooting Problem Things to check Countermeasure Nothing is Cannot start, protector activated Check short circuit of displayed. heater Cannot start, protector did not activate Can start, display faulty Replace power supply. Replace the display. The display is not Can start Replace display module. accurate. Cannot start Replace the MAIN board. The buzzer sounds The CPU board is faulty. Replace the CPU board. intermittently after the Main switch is turned ON. The START switch does not work. (RUN lamp not lit) The COOL switch does not work. (COOL lamp not lit) The MODE switch does not work. Each shift key does not work. The CHECK switch does not work. The FUNCTION switch does not work. The RUN lamp does not light. The COOL lamp does not light. The other switches do not work, either. The other switches work. The other switches do not work, either. The other switches work. The other switches do not work, either. The other switches work. The other switches do not work, either. The other switches work. The other switches do not work, either. The other switches work. The other switches do not work, either. The other switches work. The test operation is good. Cannot start Pressing the COOL switch starts the fan. Replace the MAIN board. Replace the panel switch sheet. Replace the MAIN board. Replace the panel switch sheet. Replace the MAIN board. Replace the panel switch sheet. Replace the MAIN board. Replace the panel switch sheet. Replace the MAIN board. Replace the panel switch sheet. Replace the MAIN board. Replace the panel switch sheet. Replace the PNL board. Replace the MAIN board. Replace the PNL board. 16

18 Table 2 Test Unit Troubleshooting Problem Things to check Countermeasure Samples are not heated. The heater has an open circuit. The heater has no open circuit. Replace the heater. Replace the heater SSR. The heater output does not become OFF. Go to the I/O check mode, Set SSR off and then RL on, Heater output become on. The heater output is 100% after a start. Replace the heater SSR. Replace the MAIN board. The cooling fan does not operate. 24VDC is supplied to the fan. 24VDC is not supplied to the fan. Replace the cooling fan. Replace the fan SSR. The projection lamp does not light. A DC voltage (0-10V) is supplied to the Replace the lamp. lamp. No voltage is supplied to the lamp. Replace the MMB board. The receiving light quantity is small. (Occurs after starting measurement) Light is reaching the receivers. Light is not reaching the receivers. Replace the light receiver assembly. Adjust the lamp position to project light to the detectors. 17

19 5. Parts Replacement! Warning: When replacing parts, be sure to turn off the Mains switch, unplug the power cable, and wait for one minute or longer. Failure to do so may result in an electric shock or fault.! Caution: When making replacements, use genuine Tanaka parts only. 5.1 Control Unit Parts Replacement Be sure to note down the wiring arrangement before replacing parts so that the wiring can be reconnected after replacement. To remove the control unit cover, undo the four screws (two on either side) and lift the cover up (see Fig. 16). Control Unit Cover Main Board Control Unit Chassis Fixing Screws (2 on each side) Fig. 21 Side of the Control Unit (1) Replacing the CPU Board The CPU board is inserted into a socket on the MAIN board. The socket prevents reverse insertion. When inserting the CPU board, check the connector labels, CNA (CN1) and CNB 18

20 (CN2). (When viewed from the panel, the internal battery is located on the right.) (2) Replacing the ROM Insert the ROM with its notch on the CN2 side, as shown in Fig. 22. CNA (CN1) Connector code (CN1) ROM notch ROM CPU () Internal battery () Internal battery soldered on the back of the board (2 places) Connector code (CN2) CNB (CN2) CPU board Main board Front Fig. 22 The Arrangement of Parts in the Control Unit (3) Replacing the fluorescent display Disconnect the cables connected to the panel on the main board from connectors CN2 and CN3. Disconnect the power cable from CN1 on the fluorescent display board. Remove the four flat head screws from the sides of the panel and detach the panel from the main unit. Remove the four screws securing the fluorescent display and disconnect the connectors from the fluorescent display. Assemble the components in reverse order and check the cable connections. 19

21 (4) Replacing the power supply Disconnect all cables connected to the main board. Disconnect all cables connected to the 8-pin terminals of the power supply. Be sure to record the wiring in advance. (Sort the cables by terminal numbers for easy wiring.) Remove the two screws from the bottom of the control unit and detach the power supply. Attach a new power supply, wire the cables, and secure the terminals with screws. Terminal No. Number of wires Table 3 Power Supply Wiring Color Description Connect to 1 2 Orange + 5V CN1 of the MAIN board 2 1 Black Ground Ground point 3 2 Red + 12 CN1 of the MAIN board 4 1 Black Ground Ground point 5 1 White - 12 CN1 of the MAIN board 6 1 Green Frame ground Ground point 7 1 Orange AC100V-L AC terminal board 8 1 Gray AC100V-N AC terminal board 5.2 Measuring Unit Parts Replacements Be sure to record the wiring before replacing parts so that the wiring later can be reconnected afterwards. (1) Replacing the projector lamp! Caution: Do not apply strong force to the glass at the center of the lamp, or the glass may break. Remove screws from both sides of the lamp cover and detach the cover. Hold the metal sections on both sides of the lamp, and lift the lamp to remove. After replacing the lamp, reassemble the components in reverse order. (2) Replacing the light receiver assembly Remove the receiver cover to expose the light receiver assembly. Disconnect the two-pin connector from the light receiver assembly (SP-PHOTO). 20

22 Remove the light receiver assembly with the L-shaped bracket. Detach the assembly from the L-shaped bracket and replace. After replacement, reassemble the components in reverse order. (3) Replacing the heater Remove the plate from the right side of the test unit. Remove two screws from the center of the shield and detach the shield. Remove four screws from the top plate of the measuring unit and detach the top plate. Remove two screws from the sides of the light receiver mounting plate, slide the mounting plate, disconnect the cables from the light receiver assembly, and detach the mounting plate. (Before disconnecting the cables, record their colors to prevent wiring errors after replacement.) Remove four screws from the heater case at the upper part and detach the case. Record the types and order of insulators from the heater terminal board to the heater case. Remove two nuts from the heater terminals and detach the heater. Put a new heater through the hook insulator and return the electrical insulators to their original positions. Tighten the two nuts at the heater terminal board securely. Check that the heater is not contacting but isolated from the heater case. Reassemble the components (top plate, shield, and light receiver assembly) in reverse order. (Check the wiring of the light receiver assembly.) (4) Replacing the cooling fan Remove the bottom plate of the heater from the measuring unit. Remove four screws securing the heater case to the bottom plate. (A ground terminal for the heater case is on the left.) Slide the heater case and remove the fan. (Before removal, record the fan mounting status.) Attach a new fan and reassemble the components in reverse order. 21

23 ASP-5 RS-232C Instruction (1) Specification - half-duplex start-stop transmission - baud rate: 1200, 2400, 4800, or 9600 bps - data length: 7 bits - parity check: even number parity - character code: ASCII code - start bit: 1 bit - stop bit: 2 bits (2) How to change Baud Rate The factory setting is 1200bps. To alter this, remove the cover of the control unit, and then change the setting on DIP switch (SW3) on the MAIN board. Pull up Control unit cover MAIN Board Loosen cover fixing screws

24 Table 1 Baud Rate DIP SW No.1 DIP SW No.2 DIP SW No.3 DIP SW No bps OFF OFF ON ON 2400 bps OFF ON OFF ON 4800 bps ON OFF OFF OFF 9600 bps ON OFF ON OFF (3) Connection The connection to a computer is through the 25 pin or 9 pin D-Sub type connector located at the back of the control unit. An extreme care should be taken when making pin-to-pin connections, since the tester is a DTE device. (4) Pin Assignment The pin assignment is as follows: Table 2 Pin Assignment Pin # Signal Function Direction 1 GND (FG) Frame Ground 2 TXD (SD) Transmitting Data Tester Computer 3 RXD (RD) Receiving Data Computer Tester 4 RTS (RS) (Connect w/pin #5) 5 CTS (CS) (Connect w/pin #4) 6 DSR (DR) (See note-1) Computer Tester 7 GND (SG) Signal Ground 20 DTR (ER) (See note-2) Tester Computer Note-1: When starting data communication, switch this signal line to 0 logic (3V to 12V). Note-2: This signal line turns to 0 when the tester detects a flash; then turns 1 (-12V) when press RESET key. This signal is provided for user s convenience. (5) Signal Voltages Input Voltages 0 : 3V to 12V 1 : -3V to 12V Output Voltages 0 : 12V 1 : -12V

25 (6) Example for Connection As an example for the connection, connection with IBM/AT compatible is as illustrated below. Tester(25P) Computer(25P) FG 1 1 FG TXD 2 2 TXD RXD 3 3 RXD RTS 4 4 RTS CTS 5 5 CTS DSR 6 6 DSR SG 7 7 SG DTR DTR Tester(25P) Computer(9P) TXD 2 2 RXD RXD 3 3 TXD RTS 4 4 DTR CTS 5 5 GND DSR 6 6 DSR SG 7 7 RTS DTR 20 8 CTS

26 (7) Transmitted Data The data consists of ASCII coded 39 characters. It starts with STX and ends with ETX. STX A S P CR LF CR LF Instrument No. (6 ltrs) Test No. (6 ltrs) CR LF CR LF Softening Point, Left (5 ltrs) Softening Point, Right (5 ltrs) CR LF ETX Reserve ( 5 ltrs) Instrument No.: Test No.: Softening Point: The first 4 characters represent the model; last 2 the serial number. A six-digit number that is increased one by one as a test is executed properly. The number is a 4-digit number including 1 digit after decimal point. In case of the following situation, this number is replaced by character strings: The safety shut off temperature was reached, or trouble has been found. OVER_ (4 letters plus 1 space) Reserve: Normally this column is blank. In case when some trouble has been found, this number is replaced by character strings: TRBL_ (4 letters plus 1 space) (8) Operation The tester automatically transmits data as long as it is connected to a computer as described above; no other operation is necessary unless the baud rate needs to be changed. Since the tester is a stand-alone device, whether it is connected to a computer does not make any difference in its operation.

27 DRAWN NO. SHEET NO. VERSION DRAWN BY DATE

28 PT PT100 CN2 SCK-1403P CN1 SCK-1403R SP-PHOTO-1-94 PHOTO-R LAMP H A/12V SP-PHOTO-1-94 PHOTO-L PP PtA PP PtB PP PtB CN MMB 50P CN1 CN5 CN6 CN7 CN8 CN9 CN10 CN SP2 DC24V 1R CN CN4 CN R P1 FAN1 FAN2 CN MULTI-MMB SSR G3NA-220B-UTU LEGEND BK: black BL: blue BR: brown GR: green GY: gray OR: orange RD: red VL: violet WH: white Y: yellow PS CN2 BWS-24SX-U CN1 CT1 CTL-6-S-H LED2 EBR R1A MC1 TER2 T03A 5P SP-2 1R2A SP-2 DRAWN NO. SHEET NO. VERSION DRAWN BY DATE