Ametek JOFRA ATC-125 Service Manual
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Ametek JOFRA ATC-125 Service Manual

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Service Manual

Temperature Calibrator
JOFRA ATC-125/140/155/156/157/250/320/650 A/B
 Copyright 2007 AMETEK Denmark A/S

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Summary of Contents for Ametek JOFRA ATC-125

  • Page 1: Service Manual

    Service Manual Temperature Calibrator JOFRA ATC-125/140/155/156/157/250/320/650 A/B  Copyright 2007 AMETEK Denmark A/S...
  • Page 2 18-09-2007 122770...

  • Page 3: Table Of Contents

    List of contents General ..................5 1.1 Introduction ................... 5 1.2 Safety Instructions ................ 7 1.3 Adjusting and Calibrating the Instrument........8 Repairs ..................9 2.1 Service Menu ................9 2.1.1 Service Main Menu............10 2.1.1.1 Service Power Menu..........11 2.1.1.2 Service Input Menu..........
  • Page 4 3.10 Wiring Diagram – ATC-125 B ............. 81 3.11 Wiring Diagram – ATC-155 A ............. 82 3.12 Wiring Diagram – ATC-155 B ............. 83 3.13 Wiring Diagram – ATC-140/156 A ..........84 3.14 Wiring Diagram – ATC-140/156 B ..........85 3.15 Wiring Diagram –...

  • Page 5: General

    General Introduction This service manual applies to the following instruments: • JOFRA ATC-125 A/B • JOFRA ATC-140 A/B • JOFRA ATC-155 A/B • JOFRA ATC-156 A/B • JOFRA ATC-157 A/B • JOFRA ATC-250 A/B • JOFRA ATC-320 A/B • JOFRA ATC-650 A/B All calibrators are produced from quality components by skilled staff.

  • Page 6: Technical Assistance

    The following information regarding testing and repair was correct at the time of issue. Do not hesitate to contact our service department or your local distributor, if you have further queries. AMETEK Denmark A/S Gydevang 32- 34 3450 Allerød Denmark...

  • Page 7: Safety Instructions

    Safety Instructions Read this manual carefully before doing any maintenance on the instruments! Please follow the instructions and procedures described in this manual in order to maintain the instruments correctly and to avoid any personal injuries and/or damage to the instruments.

  • Page 8: Adjusting And Calibrating The Instrument

    Adjusting and Calibrating the Instrument For adjusting and calibrating the instrument we refer to the reference manual 105446, section 7.2. Please follow the guidelines in chapter 5.0 “Storing and transporting the calibrator” in the reference manual in order to care properly for the instrument after use.

  • Page 9: Repairs

    • non-original parts are used in any way when repairing the instrument. AMETEK Denmark’s liability is restricted to errors that originated from the factory. Service Menu In the Service Menu it is possible to check a number of conditions in the equipment.

  • Page 10: Service Main Menu

    Turn the equipment on while pressing the button . The start sequence stops and the following menu appears: The instrument can now be monitored while still functioning normally, however, there is no access to the functions Switch Test and Auto Step.

  • Page 11: Service Power Menu

    • Clock and date. These are set by the factory and cannot be changed from the keyboard. When AmeCal or JOFRACAL downloads work orders to the ATC, the clock is synchronised with the PC so the time stamp on the certificates follows the which has set up the ATC.

  • Page 12: Service Input Menu

    • Fan setting tells about the speed of the fan. • FPSC % control signal for Stirling engine only visible for ATC-125. 2.1.1.2 Service Input Menu Press in the Service Menu and the Service Input Menu will appear. Measurements performed by the A/D-converters are displayed in the two columns.
  • Page 13 RTD, RTD off, Ref1, Ref1 off and Cold junc. RTD off has to be between 8.300.000 and 8.500.000. RTD will have a value, which is depending on the temperature in the well. The value will vary between 10.000.000 and 16.000.000. If the value is 16.777.215 and Ref1 at the same time is below 9.000.000, there is probably an error with the Pt100 sensor in the block.
  • Page 14 RTD will have a value, which is depending on the temperature in the well. The value may vary between 10.000.000 and 16.000.000. If the value is 16.777.215 and R2 at the same time is below 9.000.000, there is probably an error with the external reference sensor. R2 must have a value between 15.000.000 and 16.700.000.

  • Page 15: Service Output Menu

    V must have a value between 32.000 and 33.500, when the inputs are short-circuited. At 10V the value has to be between 56.000 and 59.000. Press in the Service Input Menu and the AD-converter Status Menu will appear. Information on A/D-converter status. 2.1.1.3 Service Output Menu Press in the Service Main Menu and the Output Menu will...

  • Page 16: Service Keyboard Menu

    2.1.1.4 Service Keyboard Menu Press in the Service Main Menu and the Keyboard Status Menu will appear. Here the individual keys may be tested. 2.1.1.5 Service Display Menu Press followed by in the Service Main Menu and the Display Status Menu will appear. Here contrast setting is shown in %.

  • Page 17: Trouble Shooting

    Trouble Shooting Error code: Display called recursively Error message: Likely cause: Solution: Internal software error Please report error to AMETEK Denmark A/S. Error code: Error message: Display structure no. illegal Likely cause: Solution: Internal software error Please report error to AMETEK Denmark A/S.
  • Page 18 Error code: Error message: Display array structure No. illegal Likely cause: Solution: Internal software error Please report error to AMETEK Denmark A/S. Error code: Error message: Display array index mismatch Likely cause: Solution: Internal software error Please report error to AMETEK Denmark A/S.
  • Page 19 Error code: Error message: Too many slow data fields Likely cause: Solution: Internal software error Please report error to AMETEK Denmark A/S. Error code: Error message: Too many fast data fields Likely cause: Solution: Internal software error Please report error to AMETEK Denmark A/S.
  • Page 20 Main PCB (see section 2.3.1 on DIP Switch Setting) Error code: Error message: MenuLevel too high Likely cause: Solution: Internal software error Please report error to AMETEK Denmark A/S. Error code: AD-converter not responding Error message: Likely cause: Solution: Check that all voltages on the power PCB Error in communication are correct.
  • Page 21 Error: No light in display Error message: Likely cause: Solution: Defective fuse Check fuses in the mains inlet Check fuses on the Power PCB ATC-125 (F1 – F6) ATC-140/155/156/157 (F1 – F7) ATC-250/320/650 (F1 – F7) Defective regulator on Check supplies and replace PCB if Power PCB necessary Error:...
  • Page 22 Error: Calibrator does not heat (ATC-250/320/650) Error message: Likely cause: Solution: Defective well Check impedance of the heating elements (29Ω +10% - 5% for each of the main elements and 96Ω +10% - 5% for each of the top elements). For ATC-250 main 60Ω ±10% and top 200Ω...
  • Page 23 Defective Power PCB If the 3 LED’s on the Power PCB are not lit, measure the following voltages on the terminals of CN3 with the Main PCB connected. 11 (+) to 12 (-) U > 0,6V 17 (+) to 18 (-): U > 0,6V 19 (+) to 20 (-): U >...
  • Page 24 Error: Calibrator does not cool or heat sufficiently (ATC-140/156/157 only). Error message: Likely cause: Solution: Defective well Set the SET temperature to –50°C. On the Power PCB measure the voltage between CN3 and CN6 terminal 1(+) and terminal 2(-) and the voltage between CN1 and CN4 terminal 1(+) and terminal 2(-).
  • Page 25 Error: Calibrator does not cool or heat sufficiently or is slower than specified (ATC-125 only). Error message: Likely cause: Solution: Set the calibrator to –90°C Check voltages on test pins: Between GND and 24V >23V Between GND and TC_Well 1,4V+(6.20 mV/°C x T) Between GND and PWM >1V and <2V Between GND and TC_SMH 0,8V+(6.20 mV/°C x T)
  • Page 26 Pull out blue connecter on Stirling Controller PCB and measure the resistance over the Stirling engine safety termister. @23°C R ≈ 43Kohm termister If broken, replace sensor else replace Stirling Controller PCB. NB! Before replacing sensor, contact AMETEK Denmark’s Service Department for guidance. 18-09-2007 122770...
  • Page 27 1°C equals a voltage difference of approximately 40µV. If the difference is more than 200µV (5°C), the heat pipe is defect. Replace cooling unit or return calibrator to AMETEK Denmark A/S for maintenance and refilling. 122770 06 18-09-2007...
  • Page 28 Error: Switch test does not work. Error message: Likely cause: Solution: Defective Main PCB Check signal from Switch Test Input. The voltage between the terminals on the panel should be at least 4.0V. Check the signals SW-TEST(+) and SW- TEST(-) on the connector CN1 on the INPUT PCB.
  • Page 29 Supply for fan Check the voltage on the fan connector on Power PCB: On PCB with date older than 2004 (see copper print) ATC-155/156/157: ATC-320/650: On PCB with date from 2004 and newer (see copper print on PCB e.g. 040422) ATC-125/140/155/156/157: CN10 ATC-250/320/650: CN10...
  • Page 30 If RTD sensor is OK, replace Main PCB and then adjust and re-calibrate the unit. Otherwise, replace RTD sensor and re- calibrate the unit. Error: The well temperature can not become stable Error message: Likely cause: Solution: Sensor fault Check the RTD sensor. Disconnect the sensor from the PCB.
  • Page 31 Error: The RTD input is not measuring Error message: Likely cause: Solution: The current source is Set up the input measuring RTD 3-wire not working measurement. Check that the current between the lowest red terminal and the lowest black terminal is between 0.40 mA and 0.44 mA.
  • Page 32 Error: Stirring motor is not pulling stirring magnet ATC-140/250 A/B only Error message: Likely cause: Solution: Motor is broken Set stirring speed to 50. Measure voltage over CN11 on ATC-250 and CN13 on ATC-140. This should read about 18V. If this is the case, replace motor. Broken ribbon cable or If there is no signal, check that there is a 5V Main PCB...
  • Page 33 Error: Sound of internal rattling noises from the instrument. ATC-125 A/B only Error message: Likely cause: Solution: Internal piping is rattling Open the top frame and carefully bend the internal piping, until the problem is solved. Incorrect FPSC - Set the instrument in Service Mode and adjustment enter the Service Mode.
  • Page 34 Error: The instrument is locked in the opening menu Error message: Likely cause: Solution: Locked by software due Contact AMETEK Denmark A/S to wrong frequency setup 18-09-2007 122770...

  • Page 35: Supplies

    Read the product information before use. Due to flammable liquid, precautions might have to be taken. Due to transport safety regulations, the liquid is not distributed by AMETEK Denmark A/S, but is readily obtainable from your local DOW CORNING distributor. 122770 06...
  • Page 36 Inserts If an insert is placed in a well, which has not been cleaned properly, the insert might get stuck. Heating up the well, melting the oil readily solves the problem. 18-09-2007 122770...

  • Page 37: Replacement Of Spare Parts

    Replacement of Spare Parts Compare exploded views in chapter 3.0. Caution… Remember to disconnect the instrument from the mains supply before it is dismantled. Necessary tools: • Wire cutter • Screw drivers • 7 mm wrench • 2 mm Allen key •...
  • Page 38 When remounting the spill tray the screws have to be cross tightened with a force of approximately 1N/m. For best result, tighten the screws when the calibrator is heated to 80°C. This will soften the rubber seal, making the junction vertically waterproof.
  • Page 39 ATC-125 only Unscrew and remove the 4 screws in the top frame. Carefully remove the insertion funnel guide and loosen the entire top plate. Unscrew and remove the 2 screws and washers in the top frame to enable the keyboard unit to be removed.
  • Page 40 Removal of Top Frame, all Models Remove the screws and washers holding the top frame in place. ATC-125 only First remove the 6 screws holding the top plate with globe. The top frame can now be removed entirely to expose the interior of the instrument.
  • Page 41 This picture shows an ATC-250 B. This picture shows an ATC-125 B. Removal of Power PCB (Exploded views, pos. 7). ATC-140/155/156/157 A/B Mark the 2 connectors to the Peltier elements with a pen as shown on the picture, before disconnecting the connectors on the Power PCB.
  • Page 42 It is now possible to retract the small Support PCB and the Power PCB from the instrument. The small Support PCB is only found in the early models of ATC-155 A/B. ATC-250/320/650 A/B Disconnect the cables on the Power PCB. Leave the one that connects the Power PCB to the Display Unit.
  • Page 43 The connections CN108 and CN109 are parallel on the PCB, so they can be placed in any order, without any problems. All other connecters cannot be misplaced due to physical appearance. Removal of Main PCB (Exploded views, pos. 8 + 9). ATC-125/140/155/156/157 A/B After removing the top frame as described above disconnect the 4...
  • Page 44 Note… ATC-125 only The system is filled with the flammable gas propylene. Removal of Well, all Models (Exploded views, pos. 5). Please follow steps A through D for all models. Remove the thin aluminium plate placed above the transformer by pulling it up.
  • Page 45 Cut the strap holding together the cables and carefully retract the well. This picture shows the ATC-155 B calibrator. Note the position of the straps for later assembly. This picture shows the ATC-157 B. Note that the aluminium plate is mounted on the well.
  • Page 46 ATC-125 A/B Note… The well, Stirling engine, connecter tube and expansion tank, are to be considered as one unit. If any fittings in this unit are to be loosened, the entire system will not be operational. It is though possible to loosen the Stirling engine to replace the fan.
  • Page 47 Removal of Fan, all Models (Exploded views, pos. 6) Please follow steps A through E for all models Remove the 4 screws securing the fan and the protection grid in front of it. ATC-125 only Remove one side and the back panel of the instrument.
  • Page 48 Remove the air filter by loosening the 4 screws holding it. If the air filter is dirty, replace it. Now loosen the 4 nuts holding the Stirling engine. Lift the Stirling engine as little as possible to slide out the fan, max. 5cm.
  • Page 49 ATC-125/140/155/156/157 A/B Remove the M6 nut and washer with a 10-mm socket wrench. Cut the straps holding together the wires and retract the transformer after having disconnected the wires to the power-inlet module. Note the position of the straps for later assembly.
  • Page 50 From beneath: Remove the 2 screws. Retract the I/O plate after disconnecting all wires. This picture shows the input plate for an ATC- 650 B calibrator. Replacement of Reference Sensor (Exploded views, pos. 4) To replace the reference sensor in the well unit, follow steps A through D followed by step F and then follow the procedure given below.
  • Page 51 Remove the 2 screws and retract the reference sensor from the Well Unit. When remounting a new sensor, it must be placed in the hole together with 0.2ml compound. ATC-156 A/B: Place the well unit upside down and remove the 2 screws from the Connection PCB.
  • Page 52 The reference sensor is the one placed in the right hole beneath in the picture. Disconnect the 2 sensor wires from the Connection PCB. When remounting a new sensor, it must be placed in the hole together with 0.5ml compound. ATC-320/650 A/B: Place the well unit upside down with the wires pointing towards you.
  • Page 53 ATC-140 A/B: Remove the side panel by unscrewing the 4 Allen screws and the ground wire. When remounting the ground wire bee sure to replace the washers, one on either side of the cable ring tongues terminal. Place the sensor (sensor kit 125152) in the hole at the bottom of the well, together with 0.2ml compound.
  • Page 54 ATC-125 A/B: In the bottom of the well, unscrew the 4 nuts holding the sensor cover and gently remove it. Remove the outer layer of insulation - when reassembling a new insulation layer must be used. Cut the plastic strap holding together the wires from the reference sensor and the 3 thermocouples.
  • Page 55 The thermocouple is the one placed in the left hole from above in the picture. Note that there are 2 wires to be retracted. Remove the screw and the small bracket attaching the thermo- coupler to the well unit. Retract the thermocouple from the well unit.
  • Page 56 ATC-125 A/B: Remove the outer layer of insulation - when reassembling a new insulation layer must be used. Cut the plastic strap holding together the wires from the reference sensor and the thermocouples. Now the sensor can be retracted. The retracted sensor bundle consists, of 2 difference tempe- rature sensors and one safety sensor.
  • Page 57 The other end is bend 25mm from the tip of the sensor and placed in the sensor hole on top of the well. After reinstalling both ends of the sensor in the well, the wires must be strapped together. When a new sensor has been installed, a new gasket has to be installed on top of the well.
  • Page 58 Placement of Wires: Power 0,75mm Power Black 0,75mm – Signal Orange 0,25mm PIN 1 CTRL. V+ Signal 0,25mm PIN 4 Drv. Sig. Signal Brown 0,25mm PIN 5 CN7 Error Signal Black 0,25mm PIN 8 0V out DIP-Switch Settings: Note… Instruments should be reassembled in reverse order. Ensure that all parts are in good working order and that all wires are connected correctly.

  • Page 59: Dip-Switch Settings

    2.3.1 DIP-Switch Settings The difference between version 1 and version 2 is described as follows: PCB type Version 1 Version 2 Main PCB 4 pole DIP-Switch 5 pole DIP-Switch None 8 pole DIP-Switch Power PCB Main PCB Version 1 main board with version 1 power PCB. When version 1 Main PCB’s (A and B model) are connected to version 1 Power PCB’s, the DIP-Switch Settings on the Power PCB are as follows:...

  • Page 60: Configuring The Power Pcb For Atc-320 A/B (Version 1)

    When connecting new Main PCB’s to old Power PCB’s they must be connected with a cable 125232. Power PCB ATC-125 There is no DIP-Switch on the power PCB for the ATC-125 and the Power PCB has no need for any further adjusting or configuration. New Power PCB with new Main PCB When version 2 Power PCBs are connected to version 2 Main PCBs, the DIP-Switch Settings on the Power PCBs are as follows:...

  • Page 61: Configuring The Power Pcb For Atc-320 A/B (Version 2)

    2.3.3 Configuring the Power PCB for ATC-320 A/B (version 2) When setting up a ATC-320 A or B with version 2 Power PCB, one terminal on U15 must be disconected. See drawing below. 2.3.4 Configuring the Power PCB for ATC-650 A/B (version 1) Remove the resistor R20 from the Power PCB.

  • Page 62: Mvi Circuit For Atc-250/320/650 A/B

    Adjustment – ATC-155 A/B Turn the pre-set potentiometer R9 clockwise as far as possible. Switch the calibrator on using the power control switch. Set the calibrator to –50°C. Connect a voltmeter to CN8. Adjust R9 until the voltage for CN8 reaches a) 0.45V for PCB marked PCB 991025 b) 0.41V for PCB marked PCB 010125 or the latest PCB.
  • Page 63 Adjustment Turn the pre-set potentiometer R37 counter clockwise as far as possible. The calibrator is started in service mode by pressing and holding while the calibrator is switched on. Press (SET temp.) and set the calibrator to max. temperature (250°C, 320°C or 650°C) and press ”ENTER”. Press (Service) and then .

  • Page 64: Spare Parts And Drawings

    Spare Parts and Drawings Spare Parts All parts listed in the lists of spare parts can be obtained from the factory through your dealer (see exploded views). 18-09-2007 122770...
  • Page 65 List of Spare Parts – ATC-125 A/B Pos. Number Spare Parts (Compare exploded view section 3.2) 126395 I/O Power plate with RS232 126396 Display module with keyboard and PCB board 126397 I/O Plate without sensor input A model only 126398 I/O Plate with sensor input B model only 126399 Reference sensor...
  • Page 66 List of Spare Parts – ATC-140 A/B Pos. Number Spare Parts (Compare exploded view section 3.3) 123125 I/O Power plate with RS232 123127 Display module with keyboard and PCB board 123128 I/O Plate without sensor input A Models only 123129 I/O Plate with sensor input B Models only 125155 Reference sensor...
  • Page 67 List of Spare Parts – ATC-155 A/B Pos. Number Spare Parts (Compare exploded view section 3.4) 123125 I/O Power plate with RS232 123127 Display module with keyboard and PCB board 123128 I/O Plate without sensor input A Models only 123129 I/O Plate with sensor input B Models only 123130 Reference sensor...
  • Page 68 List of Spare Parts – ATC-156 A/B Pos. Number Spare Parts (Compare exploded view section 3.5) 123125 I/O Power plate with RS232 123127 Display module with keyboard and PCB board 123128 I/O Plate without sensor input A Models only 123129 I/O Plate with sensor input B Models only 123781 Reference sensor...
  • Page 69 List of Spare Parts – ATC-157 A/B Pos. Number Spare Parts (Compare exploded view section 3.6) 123125 I/O Power plate with RS232 123127 Display module with keyboard and PCB board 123128 I/O Plate without sensor input A Models only 123129 I/O Plate with sensor input B Models only 126035 Reference sensor...
  • Page 70 List of Spare Parts – ATC-250 A/B Pos. Number Spare Parts (Compare exploded view section 3.7) 123126 I/O Power plate with RS232 123127 Display module with keyboard and PCB board 123128 I/O Plate without sensor input A Models only 123129 I/O Plate with sensor input B Models only 125169 Reference sensor...
  • Page 71 List of Spare Parts – ATC-320/650 A/B Pos. Number Spare Parts (Compare exploded view section 3.8) 123126 I/O Power plate with RS232 123127 Display module with keyboard and PCB board 123128 I/O Plate without sensor input A Models only 123129 I/O Plate with sensor input B Models only 123131 Reference sensor...
  • Page 72 Schedule for use of ribbon cable pos. 16 No. of pins Main PCB connector Power PCB connector Part no. 105580 125231 125232 124978 18-09-2007 122770...

  • Page 73: Exploded View - Atc-125 A/B

    Exploded View – ATC-125 A/B 3a+b Exploded view ATC-125 A/B 126614 00 122770 06 18-09-2007...

  • Page 74: Exploded View - Atc-140 A/B

    Exploded View – ATC-140 A/B (0,35:1) 03-01-2005 18-09-2007 122770...

  • Page 75: Exploded View - Atc-155 A/B

    Exploded View – ATC-155 A/B 122770 06 18-09-2007...

  • Page 76: Exploded View - Atc-156 A/B

    Exploded View – ATC-156 A/B 18-09-2007 122770...

  • Page 77: Exploded View - Atc-157 A/B

    Exploded View – ATC-157 A/B 122770 06 18-09-2007...

  • Page 78: Exploded View - Atc-250 A/B

    Exploded View – ATC-250 A/B Målstok: Line æ re m ål Tegner (0,34:1) GYDEVANG 32 - 34 Dato: Tegn. format DK - 3450 ALLER ØD 03-01-2005 TEL.: +45 48168000 Emnebetegnelse Erstatter: Rev nr.: Tegnings nr: ATC-250 Kompl. 125174 Rev./ Dok./ Ændring: dato init.

  • Page 79: Exploded View - Atc-320/650 A/B

    Exploded View – ATC-320/650 A/B 122770 06 18-09-2007...

  • Page 80: Wiring Diagram - Atc-125 A

    Wiring Diagram – ATC-125 A 18-09-2007 122770...

  • Page 81: Wiring Diagram - Atc-125 B

    3.10 Wiring Diagram – ATC-125 B 122770 06 18-09-2007...

  • Page 82: Wiring Diagram - Atc-155 A

    3.11 Wiring Diagram – ATC-155 A 18-09-2007 122770...

  • Page 83: Wiring Diagram - Atc-155 B

    3.12 Wiring Diagram – ATC-155 B 122770 06 18-09-2007...

  • Page 84: Wiring Diagram - Atc-140/156 A

    3.13 Wiring Diagram – ATC-140/156 A 18-09-2007 122770...

  • Page 85: Wiring Diagram - Atc-140/156 B

    3.14 Wiring Diagram – ATC-140/156 B 122770 06 18-09-2007...

  • Page 86: Wiring Diagram - Atc-157 A

    3.15 Wiring Diagram – ATC-157 A 18-09-2007 122770...

  • Page 87: Wiring Diagram - Atc-157 B

    3.16 Wiring Diagram – ATC-157 B 122770 06 18-09-2007...

  • Page 88: Wiring Diagram - Atc-250/320/650 A

    3.17 Wiring Diagram – ATC-250/320/650 A 18-09-2007 122770...

  • Page 89: Wiring Diagram - Atc-250/320/650 B

    3.18 Wiring Diagram – ATC-250/320/650 B 122770 06 18-09-2007...

This manual is also suitable for:

Jofra atc-140Jofra atc-320Jofra atc-250Jofra atc-650 aJofra atc-650 bJofra atc-155 ... Show all

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