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Maintenance Manual
Ver 2.0 100501
Thank you for purchasing the APM-7 Automated Flash Point Tester, manufactured by
Tanaka Scientific Limited.
This manual contains all necessary information for the proper maintenance of the
APM-7 unit (possible readjustments, treatment of malfunctions, exchange of parts, etc.).
Before performing any maintenance on the APM-7, read this manual carefully and make
sure that you fully understand the instructions given herein.
In order to ensure safe operation of the APM-7 Flash Point Tester, this manual makes
use of warnings and caution messages such as those below. To avoid personal injury
and/or equipment damage, strictly observe these important safety precautions at all
times.
!
・ Warning:
Improper use and/or negligence may result in serious
personal injury or death.
・ Caution:
!
Improper use and/or negligence may result in personal
injury or equipment damage.
● This manual addresses all users of the APM-7 Automated Flash Point Tester. It is
presumed that the user is familiar with related ISO and ASTM standards, and has
experience in working with potentially dangerous articles.
● Although this manual has been written and edited with the utmost care and attention,
users are kindly asked to report possible misspellings and omissions, as well as
other errors in the text (inaccuracies or missing parts) to the manufacturer or an
authorized distributor.
● Before performing any maintenance work on the APM-7, thoroughly read this manual
and ensure that you fully understand all the instructions given herein. If you are
unclear or have questions, even if seemingly insignificant, always contact the
manufacturer or an authorized distributor.
● Store the manual in a safe and convenient location (preferably near the equipment)
for future reference.
● When reading the manual, pay special attention to the sections that are indicated
with “Warning” and “Caution”. Please ensure that you fully understand the
instructions given and strictly observe these precautions at all times.
Strictly observe the instructions for safe use of the equipment at all times.
Negligent disregard of the safety precautions outlined below may not only
lead to equipment damage, but also result in serious personal injury or
death.
Tanaka Scientific Limited will not be liable for any damage or injury resulting
from user negligence.
! Warning: Never touch the ignition coil and/or any electric components of
・
the equipment when performing gas leak inspection. Touching
any of the above components may cause serious burns or
electrical shock, as the unit is powered during gas leak
inspection.
・ Warning: Take extra care to avoid naked flames, sparks, etc. when
!
performing gas leak inspection.
Extreme danger of fire and/or explosion.
!
・ Warning: Never touch heating elements of the APM-7 with bare hands
when operating the device. These parts produce extreme heat
and may cause serious burns.
!
・ Warning: Never use bare hands to remove a test cup after completion of a
test sequence. A danger of serious burns remains even after
equipment has cooled down.
!
・ Warning: Always turn off the main switch and remove the power plug from
the wall socket before exchanging spare parts.
Exchanging spare parts while the unit is powered up may result
in electrical shock or equipment breakdown.
<Preface>
Foreword ........................................................................... 1
About this Manual .................................................................... 1
Before starting Maintenance Work ...................................................... 2
Safety Precautions (“Warning” and “Caution” indicators) .................................. 2
1 Periodic Inspections ............................................................ 6
1.1 Cleaning of Test Cup and Test Cover.......................................... 6
1.2 Confirmation of temperature correction value ................................... 6
1.3 Confirmation of displayed temperature......................................... 6
1.4 Gas Leak Inspection ........................................................ 6
2 Adjustments ................................................................... 9
2.1 Filament Output Settings .................................................... 9
2.2 Parameter Settings ........................................................ 11
2.3 Displaying Temperature Unit and Temperature Correction....................... 12
2.3.1 Displaying Temperature Unit ............................................ 12
2.3.2 Temperature Calibration ................................................ 12
2.3.3 Displaying Temperature Correction ....................................... 13
2.4 External Output Settings .................................................... 14
2.4.1 RS-232C Setting....................................................... 15
2.4.2 Sample ID (appears when selected Printer only) ........................... 19
2.5 Time settings (appears when RS_232C setting is Printer, and valid when built in clock is
equipped) ........................................................................ 20
2.6 Barometric Pressure Sensor Calibration (appears when built-in barometric pressure
sensor is equipped)................................................................ 20
2.7 Optional Mode Settings..................................................... 21
2.7.1 User Mode Settings .................................................... 21
2.7.2 Simulated TAG Mode................................................... 23
2.8 Safety Practice ............................................................ 23
3 Troubleshooting ............................................................... 24
3.1 Trouble Message and Treatment ............................................ 24
3.2 Trouble Shooting for Each Unit .............................................. 26
3.2.1 Control Unit ........................................................... 26
3.2.2 Test Unit.............................................................. 27
4 Replacement of Spare Parts .................................................... 29
4.1 Replacement of Control Unit Components..................................... 29
4.1.1 CPU Board ........................................................... 30
In order to maintain accurate performance of the APM-7 and to guarantee safe oparation of the
device, periodic inspections must be performed at regular intervals.
! Caution: Do not bend the tip of the flash detector when cleaning test cover.
If the tip of the flash detector is bent, sensitivity deteriorates and
thus flash detection may be missed.
(1) Clean Test Cup using some solvents if there is some deposit in the cup. Use wire brush if the
deposit can not be removed by solvent. Wrong results may be obtained if some deposit in
the cup.
(2) Clean Test Cover using some solvents once in a week. If some sample sticks to the test
cover, the function of the shutter and ignition source application may be wrong, and it causes
wrong results. Clean the cover using some solvents by pushing arm rod which is for manual
application. Dry the cover well before the next test.
・ Warning: Never touch the ignition coil and/or any electric components of
!
the equipment when performing gas leak inspection. Touching
any of the above components may cause serious burns or
electrical shock, as the unit is powered during gas leak
inspection.
Follow the instructions below to check the gas lines of the APM-7 unit for possible leaks.
(1) Turn OFF the main switch and remove the power plug from the wall socket.
(2) Remove windscreen.
(3) Remove signal connecting cable and power connecting cable from the test unit.
(4) Remove rear cover and then side covers of the test unit. See Fig. 1.
Windscreen
Side Cover
Lift up then slide back
to remove
(5) Re-connect signal connecting cable and power connecting cable to the test unit.
(6) Reinsert the power plug to the wall socket and turn ON the main switch.
(7) Press the Up-Down key and RESET key, then consecutively release the RESET key and
then the Up-Down key. The following I/O Checking Screen will appear.
APM HE GV CL FL NZ KA KB
Gas flame of of of of of of of
Temp Detect Fuse NZ_Stop Arm
23.5 3.5 * *
Fig. 2 I/O Checking Screen
By pressing Right-Left key to select item, then press FUNCTION key to display each setting
screen. For the changing value, press Right key to blink the first character, then press Right-Left
key/ Up-Down key. Press RESET key after setting is completed.
Record changed value to “Appended Table 1 APM-7 Setting Table”. It will be required when
built-in battery goes dead (approx. 5 to 7 years).
- Gas Ignition: After entering new output value, push START key to confirm the gas can be
ignited by filament within a minute. If the tester is not used for a long time, it may take a few
minutes to bleed the air out of the gas piping. If the gas is coming out but not ignited by
filament, increase output value.
- Electric Ignition: After entering new output value, run a test using CRMs. Increase set output
value if the obtained flash point was higher than expected; decrease it if lower than expected.
If the obtained flash point was within a range, decrease the set output value by 5%, and then
run a test again. The lowest output when the obtained flash point is still within the acceptable
range is the best setting for the extended life of the igniter.
By selecting Ignit (off is blinking), and pressing Up-Down key to turn ignition on, electric igniter
will be lighting and actual output (A) can be seen.
APM Filament
Ignit. sourc
Gas flame
Set output Ignit Current
40 % on 3.8(A)
Fig. 5 Filament Output Setting Screen (lighting)
10
Too strong an initial heat would cause hunching of temperature rise rate. Too weak an initial
heat could not reach the set rate. Please input an even number (every 2%).
(2) Cool (Cooling Time)
Cooling time can be change from 00min (No Cooling) to 99min(Continuous Cooling).
(3) First appl (First Application Temperature below EXP.FP)
For APM-7, the temperature of first application of ignition source is changeable. The range is
18 oC (32 oF) to 28 oC (50 oF) bolow the expected flash point.
11
12
Temp(oC) POS 0 40 80
41oC
Offset +0.0 +0.0 +1.0 -1.0 40oC
0oC
0oC 40oC 80oC
Actual Value of the Temperature Sensor
13
(1) RS_232C
Computer: Data will be transmitted to connected PC after detecting flash point by free run
method. (EXP.FP, FP, etc.) See 2.4.1.
Printer: Data will be transmitted to connected printer (*1) after detecting flash point.
(EXP.FP, FP, Sample ID, Time, etc.)
14
Pull up
Control unit
MAIN Board
15
(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.
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.
16
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 20 20 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
17
STX A P M 7 5 4 CR LF 0 0 0 0 0 1 CR LF
0 8 5 . 0 CR LF 0 9 0 . 0 CR LF
0 1 6 . 0 CR LF ETX
No. of
Applications
Instrument No.: The first 4 characters represent the model; last 2 the serial number.
Test No.: A six digit number which is increased one by one as a test is executed
properly.
Flash Point: 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:
Trouble during a test.
“TRBL_” (4 letters plus 1 space)
The flash point is detected during the first application.
“UNDER” (5 letters)
The actual flash point exceeded the safety cut temperature.
“OVER_” (4 letters plus 1 space)
No. of applications: The number of ignition source applications when the flash point is
detected. (If the flash point is detected at the 10th application, the value is
“010.0”.)
(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.
18
After selected Sample ID Y, press RESET key to return MAIN screen, press FUNCTION
key twice, the following Sample ID Entering Screen will appear.
Sample
AAAAAAAA
Press Right-Left key to move cursor, and then change the character by pressing Up-Down
key. It consists of Arabic numerals (0 to 9), alphabet (A to Z) and some characters (space !
“ # $ % & ‘ ( ) * + - . / ).
19
Press Right-Left key to select figure in the Set Value line (blinking), then change the settings
by pressing Up-Down key. The set value data will move to the Date Time line by Pressing
FUNCTION key.
2.6 Barometric Pressure Sensor Calibration (appears when built-in barometric pressure sensor
is equipped)
Press Right-Left key to select Baro cal (blinking) from the MENU screen, then press
FUNCTION key. The following screen will appear.
Press Right-Left key to select figure below the Set Value (blinking), then change the settings
by pressing Up-Down key. The set value data will move to under the Baro by Pressing
FUNCTION key.
20
(7) Press Right-Left key to select User mode or S_TAG (Invalid is blinking), then press
Up-Down key to be valid. It is impossible to set both modes are valid. When user mode is
valid, Press FUNC to next screen appears lower side of the display.
(8) After finish settings, turn off the bit No.1 of the DIP switch and then press RESET key.
(9) Attach the cover of Control Unit.
APM Menu
Heat Appl Stirrer
21
Press Right-Left key to blink the heating rate, and then change the value by pressing
Up-Down key.
After selected heating rate, press FUNCTION key to return Menu screen.
Press Right-Left key to select (blinking) the interval temperature (< EFP-28) or (>=EFP-28)
or Application start temperature, then change the value by pressing Up-Down key.
After selected heating rate, press FUNCTION key to return Menu screen
22
Press Right-Left key to blink stirrer speed, then select High (250 rpm) or Low (100 rpm)by
pressing Up-Down key.
After selected stirrer speed, press FUNCTION key to return Menu screen.
2.8 Safety Practice (Applicable on ASTM A & B mode, not applicable on ASTM C mode)
Safety practice of every 10°C dipping for an expected flash point above 130 ° C can be
turned off or changed the threshold temperature, (Ver.7FP51F.ROM or later)
Press the FUNCTION, Down key and RESET key, then consecutively release the RESET
key and then the FUNCTION and Down key. The following Safety Practice Setting Screen
will appear. Change on/off or threshold temperature by Up-Down key and move the cursor by
Right-Left key.
APM
Safety Practice: on
EFP > 130 oC Appears when Safety
Practice is on.
23
If you ever experience trouble with the equipment, as a rule always notify the manufacturer or an
authorized distributor. Contact addresses and telephone numbers are listed in the “Product
Guarantee” appended to the “Instruction manual”.
Always describe the nature of the problem as clearly as possible when notifying the
manufacturer or an authorized distributor.
To address equipment trouble, one of the following 2 procedures usually apply.
① The manufacturer ships the spare parts required to repair the component responsible for the
malfunction. Replacements and inspections are executed by the user or a local agent.
② The user sends the entire unit or the malfunctioning components to the manufacturer, where
the equipment is repaired. Depending on the location, it is possible that the manufacturer may
dispatch an agent to pick up the equipment.
24
test again.
TROUBLE
THERMOFUSE BLOWN Thermofuse is blown Replace Thermofuse
25
Nothing is appeared on the Testing cannot be Circuit protector Push circuit protector pin back
display started has been activated into its original position
activated
START key does not work Other keys do not work also Replace MAIN board
COOL/WORM key does not Other keys do not work also Replace MAIN board
MODE key does not work Other keys do not work also Replace MAIN board
Up-Down, Right-Left key Other keys do not work also Replace MAIN board
does not work Other keys work properly Replace panel switch sheet
CHECK key does nor work Ignition source application is not carried Replace MAIN board
26
Sampler does not heat Heater burnt out Replace band heater
Ignition source application Stop position sensor (photo micro Replace photo micro sensor
Tester does not work all Power supply for test unit is defective Replace power supply
functions except heating
Check DC voltage on the MMB board when following symptom has occurred.
- Gas is not coming out from the nozzle when test starts.
- Cooling Fan does not work.
- Ignition application does not work (never dip).
APM HE GV CL FL NZ KA KB
Gas flame of of of of of of of
Temp Detect Fuse NZ_Stop Arm
23.5 3.5 * *
Fig. 19 I/O Checking Screen
(8) Perform following inspections according to the Occurrence.
27
28
・ Warning: Always turn off the main switch and remove the power plug from
!
the wall socket before exchanging spare parts.
Exchanging spare parts while the unit is powered up may result
in electrical shock or equipment breakdown.
29
Connector (CNB) ROM Connector (CNA) Built-in Clock Board Connector (RTC)
MAIN Board
RTC
BAROMETER
REF2
Internal Battery
CPU Board
Front Rear
4.1.2 ROM
As shown in Fig. 21, insert the ROM so that the indentation faces the CNB connector.
30
Arm Cover
Windscreen
Fixing Screw
Windscreen
Windscreen Guide
Rear Cover
Fixing Screw
Side Cover
(Slide Up, then
Slide Backward)
Rear Cover
(Slide Backward)
Side Cover
Fixing Screw
Temperature Sensor
Flash Detector
R W B
W
R
W : White
B : Black
Arm Cover
Side View
Fig. 23 Arm
31
Orientation Guide
Ground Terminal
Match Mark
32
Band Heater
33
Socket
Reflector
Photo Micro Sensor
The reflector covers
Motor Shaft
the photo micro sensor
Height Adjuster
! Caution: Adjust filament output when a new igniter is installed. See 2.1
on page 9 to 10.
Insert a thin Phillips driver to the center hole of the igniter terminal. Hold the connector of
the igniter, then pull out it with pushing driver. See Fig. 28.
34
Arm Cover
Pilot Mount
Flame Nozzle
Insulator
Insert new electric igniter to the mount fully with the insulator of the igniter facing downward
(soldered part facing upward), and fix it by tightening the knurled screw.
Twist wires of the electric igniter, put connectors of the igniter into the terminal. There is no
polarity on the electric igniter, and no need to push the driver to the center hole of the igniter
terminal. Confirm that each of the coiled electric heater is not touching each other and igniter
wires will be not pulled out without pushing center hole.
When the electric igniter is used as ignition source, confirm that the coil of the electric
igniter never touch to the test cup. The procedure is as follows.
(1) Pull out the AC power code from wall socket
(2) Set the test cup and test cover.
(3) Dip the igniter manually (press dipping rod) to confirm the ignition coil does not touch
the test cover. if the coil touches the test cover, adjust the position and dipping angle of
the igniter. See Fig. 32
35
Dipping Angle
Soldered Part
Knurled Screw
Insulator
(8) Confirm that each of the coiled electric heater is not touching each other.
(9) Set the test cup and test cover, and the dip the igniter manually (press dipping rod) to
confirm the ignition coil does not touch the test cover. If the coil touches the test cover,
adjust its position by loosing knurled screw, and the dipping angle by loosing set
screws.
(10) Remove rear cover of test unit.
(11) Turn the slide switch (SW2) from G (up) to E (down). SW2 is located on MMB board.
36
SW2
E
Fig. 31 MMB Board
(12) Turn the MAIN switch ON, and confirm the character of “Electric” appears on the Main
screen. Gas solenoid valve will never open by this operation.
(13) Change the filament output level to the value of 75 to 90%. See page 9 Chapter 2.
1.
(14) Adjust the filament output level and dipping angle again so that the obtained flash
point will correct. Be careful that the ignition coil does not touch the test cover.
Dipping Angle
37
S/N:
Name:
Date:
Temperature Offset Value
POSI( ) 000 ( ) 040 ( ) 080 ( )
120 ( ) 160 ( ) 200 ( ) 240 ( )
280 ( ) 320 ( ) 360 ( ) 400 ( )
Spare
POSI( ) 000 ( ) 040 ( ) 080 ( )
120 ( ) 160 ( ) 200 ( ) 240 ( )
280 ( ) 320 ( ) 360 ( ) 400 ( )
Parameter, etc.
First Application
Initial Heat Cooling Time External Output
Temp.
( ) ( ) ( ) ( )
38
Power Supply
Panel
Power Supply
Start Relay
Solenoid Valve for Gas
39