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Pensky-Martens Closed Cup
Automatic Flash Point Tester
Model APM-7
Maintenance Manual
Ver 2.0 100501
Tanaka Scientific Limited
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1
Foreword
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.
About this Manual
● 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.
● Contents of this manual such as specifications of functions and performance
properties of the device may be changed without notice.
● If this manual is lost or damaged, please contact the manufacturer or an authorized
distributor to order a replacement.
● 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.
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Before starting Maintenance Work
● 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.
● Always strictly observe the work instructions given in this manual.
● 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.
Safety Precautions (“Warning” and “Caution” indicators)
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.
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・ Warning： If the equipment makes strange noises or exhibits abnormal
behavior during operation, stop operation at once and turn off
the main switch. Cease using the APM-7 and immediately
contact the manufacturer or an authorized distributor.
・ 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： Refrain from assessing equipment malfunction yourself, even in
apparently trivial cases. Always contact the manufacturer or an
authorized distributor if equipment does not function properly.
・ Warning： Repairs and maintenance work other than described in this
manual may be performed only by certified service personnel.
・ 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.
・ Warning： Never use consumables, accessories and/or spare parts other
than genuine articles provided by the manufacturer, or products
specified as suitable by the manufacturer.
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Contents
＜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
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４.１.２ ROM ................................................................. 30
４.１.３ Internal Battery ........................................................ 30
４.１.４ Barometric Pressure Sensor (option) ..................................... 30
４.１.５ Built-in Clock board (option) ............................................. 30
４.２ Replacement of Test Unit Components ....................................... 31
４.２.１ Temperature Sensor ...................................................31
４.２.２ Flash Detector......................................................... 32
４.２.３ Heater Block .......................................................... 32
４.２.４ Photo Micro Sensor .................................................... 34
４.２.５ Electric Igniter .........................................................34
４.２.６ Interchange of the Ignition Source (Gas Æ Electric)......................... 35
Appended Fig. 1 Control Unit Parts Position
Appended Fig. 2 Test Unit Parts Position
Appended Fig. 3 Control Unit Wiring Diagram
Appended Fig. 4 Test Unit Wiring Diagram
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１ Periodic Inspections
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.
１.１ Cleaning of Test Cup and Test Cover
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.
１.２ Confirmation of temperature correction value
(once per month)
Confirm temperature correction value is right or not by the procedure described in section ２.３.
３.
１.３ Confirmation of displayed temperature
(perform once per 3-months)
Confirm displayed temperature is agree with mercury thermometer or not by the procedure
described in section ２.３.１ to ２.３.３.
１.４ Gas Leak Inspection
(once per 3-month for outside and once per year for inside the tester if using gas ignition)
・ 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.
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・ Warning： Take extra care to avoid naked flames, sparks, etc. when
performing gas leak inspection.
Extreme danger of fire and/or explosion.
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.
Rear Cover
Fixed Screws
Side Cover
Fixed Screws
Side Cover
Lift up then slide back
to remove
Slide back to remove
Windscreen
Fig. 1 Removing Rear Cover and Side Covers
(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.
Fig. 2 I/O Checking Screen
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 * *
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(8) Press Right key twice to blink the of under the GV.
(9) Pressing Up key will open the solenoid valve and start gas flow.
(10) Use a soft brush to apply soapy water to each of the gas line joints and check for bubbles.
Bubbles appearing at any of the gas line joints indicate the presence of a gas leak. Cease
using the APM-7 and contact the manufacturer or an authorized distributor for repairs.
(11) After completion of the inspection, press the RESET key. This will shut the solenoid valve.
(12) Turn OFF the main switch and remove the power plug from the wall socket.
(13) Remove signal connecting cable and power connecting cable from the test unit.
(14) Attach side covers and then rear cover to the test unit.
(15) Re-connect signal connecting cable and power connecting cable to the test unit.
(16) Reinsert the power plug into the wall socket to conclude gas leak inspection.
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２ Adjustments
Adjustment of Indicated temperature correction, Initial heat value and some another parameter is
done by pressing panel keys. The operation procedure is as follows.
Press the FUNCTION key and RESET key, then consecutively release the RESET key and then
the FUNCTION key. The following MENU Screen will appear.
Fig. 3 MENU 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).
２.１ Filament Output Settings
Caution: Adjust filament output when a new igniter is installed. If
filament output value is high, the electric ignitor may be burnt
out in a short time.
Tanaka Scientific Limited will not be liable for burnt out
igniter, if appropriate adjustment was not carried out by the
user.
Each piece of igniter has a slightly different resistance and thus when a new piece is installed
supplied electric power needs to be adjusted. For the replacing procedure, see 4.2.5 on page 34.
Press Right-Left key to select Filament (blinking) from the MENU Screen, then press
FUNCTION key. The following Filament Output Setting Screen will appear.
Press Right-Left key to select Set output (output value is blinking), then change the output
value by pressing Up-Down key. The provisional values are as follows. If the AMP-7 is now in
APM
Ver x.xF
Filament Para set Temp cal
Ext. out Time set Baro cal
appears when selected Printer only
See page 15 ２.４ and page 21 ２.
５.
appears when built-in Barometric
Pressure Sensor is equipped. See page
21 ２.６.
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electric ignition configuration, enter provisional output value or 10% lower than the present setting.
Table 1 Filament Output Values
Provisional Output Value Actual AC
Source
Gas Ignition Electric Ignition
100V 30% 65%
110V 25% 60%
115V 25% 55%
120V 20% 50%
220V 30% 65%
230V 25% 60%
240V 20% 55%
- 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.
Fig. 4 Filament Output Setting Screen
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.
Fig. 5 Filament Output Setting Screen (lighting)
APM
Filament Ignit.source
Gas flame
Set output Ignit
40 % off
APM
Filament Ignit. sourc
Gas flame
Set output Ignit Current
40 % on 3.8(A)
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２.２ Parameter Settings
Press Right-Left key to select Para set (blinking) from the MENU Screen, then press
FUNCTION key. The following Parameter Setting Screen will appear.
Press Right-Left key to select items (each value is blinking), then change the value by pressing
Up-Down key.
The explanations of each item are as follows.
(1) I.heat (Initial Heat)
Standard Value is as follows.
Table 2 Initial Heat Values
AC Source 100V 110V 115V 120V 220V 230V 240V
Standard Value 26 24 22 20 22 20 18
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
o
C (32 oF) to 28 oC (50 oF) bolow the expected flash point.
Fig. 6 Parameter Setting Screen
APM
Para set
First
I.heat Cool appl
22% 10min 22oC
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２.３ Displaying Temperature Unit and Temperature Correction
２.３.１ Displaying Temperature Unit
APM-7 is capable of displaying temperature in degree C and degree F. When APM-7 is shipped
out, temperature unit is set to degree C as default, and it can be switched to degree F as follows:
(1) Press Right-Left key to select Temp cal (blinking) from the MENU screen, then press
FUNCTION key. The following Temperature Calibration Screen will appear.
(2) Press Right-Left key to brink the temperature unit, then change the unit by pressing
Up-Down key.
(3) Press RESET key to return.
Fig. 7 Temperature Correction Screen
２.３.２ Temperature Calibration
(1) Preparation
(a) Prepare ASTM-9C and 10C mercury-in-glass thermometer. (Use ASTM 9F and 10F when
the temperature unit setting is
o
F, and convert following temperature value to degree F.)
(b) loosen 4 screws, then lift Arm Cover upward.
(c) Remove the Flash Detector from Test Cover carefully and keep it away from the Cover.
Note that the tip of Flash Detector is easily broken.
(d) Set a standard glass thermometer (ASTM 9C) through the Flash Detector Collar so that
the tip of thermometer positioned 43 - 46 mm away from inner wall of Test Cover. A silicon
stopper is useful to fit the thermometer.
(e) Record present filament output value, then set it to “0”. See ２.１.
(2) Temperature Data Recording
(a) Pour gas oil into sample cup then set it to the APM-7.
(b) Set Expected Flash Point at 100
o
C.
(c) Press “START” key to start a calibration.
(d) Record displayed temperature at every 10
o
C of thermometer readings.
(e) Press the “COOL” key to stop heating after complete the recording.
(f) change the sample to salad oil, and the thermometer to ASTM 10C, set Expected Flash
APM
Temp cal
Temp unit(oC)
Temp(oC) POS 0 40 80
Offset +0.0 +0.0 +0.0 +0.0
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Point at 370℃, then repeat the procedure (c) to (e).
(3) Calculate new correction values.
(4) Input new correction values by the manner of chapter ２.３.３.
(5) Repeat (2) again and check the displayed temperature after inputted new correction values.
(6) Return the filament output to previous value which is recorded in (1)(e).
２.３.３ Displaying Temperature Correction
(1) Multi Point Correction
This tester has temperature correction point every 40
o
C between 0 oC to 400 oC.
The relationship between actual value of the temperature sensor and the displaying
temperature is shown in Fig. 8.
Display Temperature = Actual Value of the temperature sensor + Offset Value of each
correction point
Correction between each of the temperature correction points (e.g. at 36
o
C) are determined by
linear interpolation.
APM
Temp cal
Temp unit(
o
C)
Temp(
o
C)
POS 0 40 80
Offset +0.0 +0.0 +1.0 -1.0
80oC
79
o
C
41
o
C
40
o
C
0
o
C
0
o
C40
o
C80
o
C
A
ctual Value of the Temperature Senso
r
Display Temperature
Fig. 8 Multi-Point Correction
(2) Correction by POS
This tester is able to perform correction by POS in addition to correction by each of the
temperature correction points. This is a correction value for the entire temperature range.
The relationship between actual value of the temperature sensor and the displaying
temperature is shown in Fig. 9.
Display Temperature = Actual Value of the temperature sensor + Offset Value of each
correction point + POS Offset Value
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APM
Temp cal
Temp unit(
o
C)
Temp(
o
C)
POS 0 40 80
Offset +1.0 +0.0 +1.0 -1.0
80oC
42
o
C
41
o
C
40
o
C
0
o
C
0
o
C 40oC
80oC
Actual Value of the Temperature Sensor
1oC
Previous curve
Fig. 9 Correction by POS
(3) Entering Correction Value
(a) Press Right-Left key to select Temp cal (blinking) from the MENU screen, then press
FUNCTION key. The Temperature Correction Screen shown in Fig. 7 will appear.
(b) Press FUNCTION key once. (only when the optional software is installed)
(c) Press Right-Left key to select correction point (each value is blinking), then change the
offset value by pressing Up-Down key. For the next temperature range, press
FUNCTION key.
(d) Press RESET key to return.
２.４ External Output Settings
Press Right-Left key to select Ext.out (blinking) from the MENU screen, then press
FUNCTION key. The following External Output Setting Screen will appear.
Press Right-Left key to select items (each value is blinking), then change the settings.
The explanations of each item are as follows.
Fig. 10 External Output Setting Screen
(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.)
APM
Ext.out RS_232C
Computer
Inst No. Test No.
95 0037
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*1: Use printer BS2-80TS (option). For date/time verification, we recommend that optional
Built-in Clock Board be purchased with this Printer.
(2) Inst No.(Instrument No.)
Consist of 2 digits. Outputted when a PC or a printer is connected. This number can be
changed by pressing Up-Down key.
(3) Test No.(Test Counter)
Consist of 4 digits and increase by 1 every time a normal flash point is detected. Outputted
when a PC or a printer is connected. If set at 0000 initially, the first tests prints 0001.
２.４.１ RS-232C Setting
(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 9600bps. To alter this, remove the cover of the control unit, and then
change the setting on DIP switch (SW3) on the MAIN board.
MAIN Boar
d
Loosen cover fixing
Control unit
Pull up
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Table 3 Baud Rate
DIP SW No.1 DIP SW No.2 DIP SW No.3 DIP SW No.4
1200 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 4 Pin Assignment
Pin # Signal Function Direction
1 GND (FG) Frame Ground
2 TXD (SD) Transmitting Data Tester Æ Computer
3 RXD (RD) Receiving Data Computer Æ Tes t er
4 RTS (RS) (Connect w/pin #5)
5 CTS (CS) (Connect w/pin #4)
6 DSR (DR) (See note-1) Computer Æ Tes t er
7 GND (SG) Signal Ground
20 DTR (ER) (See note-2) Tester Æ 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
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(6) Example for Connection
As an example for the connection, connection with IBM/AT compatible is as illustrated below.
FG
TXD
RXD
RTS
CTS
DSR
DTRSG20
2
1
3
4
5
6
7
FG
TXD
RXD
RTS
CTS
DSR
DTR
SG
20
2
1
3
4
5
6
7
Tester(25P) Computer(25P)
TXD
RXD
RTS
CTS
DSR
DTRSG20
2
3
4
5
6
7
RXD
TXD
DTR
GND
DSR
CTS
RTS
8
2
3
4
5
6
7
Tester(25P) Computer(9P)
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(7) Transmitted Data
The data consists of ASCII coded 39 characters. It starts with “STX” and ends with “ETX”.
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
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 10
th
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.
Instrument No. (6 ltrs)
Test No. (6 ltrs)
Flash Point (5 ltrs) EXP.P.P (5 ltrs)
No. of
A
pp
lications
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２.４.２ Sample ID (appears when selected Printer only)
Y: Sample ID function is active. Consists of 8 digits and can be entered on the Sample ID
Entering Screen.
N: Sample ID function is inactive.
Fig. 11 Sample ID Function Selecting Screen
After selected Sample ID Y, press RESET key to return MAIN screen, press FUNCTION
key twice, the following Sample ID Entering Screen will appear.
Fig. 12 Sample ID Entering Screen
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 !
“ # $ % & ‘ ( ) * + - . / ).
APM
Ext.out RS_232C
Printer
Inst No. Test No. Sample ID
95 0037 Y
Sample
AAAAAAAA
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２.５ Time settings (appears when RS_232C setting is Printer, and valid when built in clock is
equipped)
Press Right-Left key to select Time set (blinking) from the MENU screen, then press
FUNCTION key. The following Time Setting Screen will appear.
Fig. 13 Time Setting Screen
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.
Fig. 14 Barometric Sensor Calibration Screen
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.
APM
Time Set
Press FUNC key to set
Set Value 00 04/13 14:48
Date Time 00 04/13 14:48 25
APM
Baro set
Press FUNC key to set
Set Value Baro
1013 1014
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２.７ Optional Mode Settings
APM-7 has User Custom Mode and Simulated TAG Mode. Both of modes are invalid when
shipping. If these optional modes are required, change the setting. Procedure is as follows.
After this mode is entered (indicated on the screen is valid), User or S_TAG will be displayed
in the Main screen by pressing MODE key.
(1) Remove AC power code from AC outlet.
(2) Remove the cover of Control Unit (4-screws).
(3) Turn on the bit No.1 of the DIP switch (SW1) on the FP7-MAIN board.
(4) Attach the cover of Control Unit to avoid electric shock.
(5) Plug in AC cord to AC outlet, and then turn MAIN switch ON.
(6) Press RESET key. Following Optional mode Setting Screen will appear.
Fig. 15 Optional Mode Setting Screen
(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.
２.７.１ User Mode Settings
The test sequence of this mode can be customized by user’s demand. By pressing
FUNCTION key while User mode is valid, following screen appears.
Fig. 16 User Mode Setting Screen
APM
User mode S_TAG
Invalid Invalid
APM
Menu
Heat Appl Stirrer
Press FUNC to next screen
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22
(1) Heating Rate Setting
Press Right-Left key to select Heat (blinking) from the Menu screen, then press FUNCTION
key. The following screen will appear.
Fig. 17 Heating Rate Setting Screen
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.
(2) Application Setting
Press Right-Left key to select Appl (blinking) from the Menu screen, then press FUNCTION
key. The following screen will appear.
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
APM
Heat FUNC -> Menu
Rate (< EFP-56) (> EFP-28)
5.5o c/m 5.5o c/m
APM
Appl FUNC -> Menu
Interval:(< EFP-28) (>=EFP-28)
5.0
o
c 2.0o c
Appl start:EFP-050
o
c
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23
(3) Stirrer Speed Setting
Press Right-Left key to select Stirrer (blinking) from the Menu screen, then press
FUNCTION key. The following screen will appear.
Fig. 18 Stirring Speed Setting Screen
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.
２.７.２ Simulated TAG Mode
The test sequence of this mode is the same as ASTM D56, and inputted at factory.
The stirrer does not work in this mode.
The temperature rises at a rate of 1
o
C in 60+/-6 seconds when the expected flash point is
below 60
o
C, at a rate of 3 oC in 60+/-6 seconds when 60 oC or above.
The ignition source begins to apply when the temperature becomes 5
o
C below the
expected flash point. After that, the application operation is repeated at each 0.5
o
C for an
expected flash point below 60
o
C, and each 1 oC for 60 oC or above.
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
Stirrer FUNC -> Menu
High (250 rpm)
APM
Safety Practice: on
EFP > 130 oC
Appears when Safety
Practice is on.
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24
３ Troubleshooting
・ Warning： Refrain from assessing equipment malfunction yourself, even in
apparently trivial cases. Always contact the manufacturer or an
authorized distributor if equipment does not function properly.
・ Warning： Repairs and maintenance work other than described in this
manual may be performed only by certified service personnel.
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.
３.１ Trouble Message and Treatment
Countermeasures for simple problems that can be treated by the user are listed in Table 5. In
the case of equipment trouble, always consult this table before notifying the manufacturer.
！
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25
Table 5 Simple Troubleshooting Procedures
Display (Error Message) Possible cause Treatment
TROUBLE
TEMP SENSOR
Temperature sensor is found defective Replace Temperature Sensor
TROUBLE
FLASH DETECTOR
Flash Detector is found defective Replace Flash Detector
TROUBLE
FIRE? (by detector)
Flash Detector detects “Fire” Extinguish the fire.
TROUBLE
FILAMENT BREAK
Electric Igniter is found defective Replace Electric Igniter.
TROUBLE
REPLACE BATTERY
Built-in Battery has expired Replace Battery.
TROUBLE
ARM POSITION
Arm is not set in place Set the Arm to the original
position before test start.
TROUBLE
MOTOR OVERLOAD
Stirring motor is stopped Press START key while this
trouble message is shown in the
display. Specimen will be heated
without stirring. Once turn MAIN
switch OFF after heat the
specimen, then turn MAIN switch
ON after 5 second, then start the
test again.
TROUBLE
THERMOFUSE BLOWN
Thermofuse is blown Replace Thermofuse
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26
３.２ Trouble Shooting for Each Unit
３.２.１ Control Unit
Occurrence Possible cause, Check point Treatment
Circuit protector
has been activated
Push circuit protector pin back
into its original position
Testing cannot be
started
Circuit protector
has not been
activated
Replace switching power supply
Nothing is appeared on the
display
Testing can be
started
Display is
defective
Replace display module
Testing can be started Replace display module Displayed screen is not
normal
Testing cannot be started Replace NAIN board
Buzzer sounds
continuously when power is
turned ON
CPU board malfunction Replace CPU board
Other keys do not work also Replace MAIN board START key does not work
Other keys work properly Replace panel switch sheet
Other keys do not work also Replace MAIN board COOL/WORM key does not
work
Other keys work properly Replace panel switch sheet
Other keys do not work also Replace MAIN board MODE key does not work
Other keys work properly Replace panel switch sheet
Other keys do not work also Replace MAIN board Up-Down, Right-Left key
does not work
Other keys work properly Replace panel switch sheet
Ignition source application is not carried
out automatically during a test
Replace MAIN board CHECK key does nor work
Ignition source application carried out
automatically during a test
Replace panel switch sheet
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27
３.２.２ Test Unit
Occurrence Possible cause, Check point Treatment
Heater burnt out Replace band heater Sampler does not heat
Heater is OK Replace heater relay and/or start
SSR
Ignition source application
does not stop
Stop position sensor (photo micro
sensor) in arm is defective
Replace photo micro sensor
Stirrer does not work Stirrer motor is defective Replace motor
Tester does not work all
functions except heating
Power supply for test unit is defective Replace power supply
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).
Checking method is as follows.
(1) Prepare digital or analog multitester
(2) Turn OFF the main switch and remove the power plug from the wall socket.
(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.
(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.
Fig. 19 I/O Checking Screen
(8) Perform following inspections according to the Occurrence.
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 * *
Page 29
28
- Gas is not coming out from the nozzle when test starts.
(1) Remove CN5 connector from MMB board.
(2) Press Right key twice to blink the of under the GV.
(3) Pressing Up key to turn on.
(4) Measure the voltage between GND and 3
rd
pin on the CN5.
DC voltage is +24V
Æ Solenoid valve for gas is defective.
DC voltage is 0V
Æ MMB board is defective.
(5) Replace defective part.
- Cooling Fan does not work.
(1) Remove CN6 connector from MMB board.
(2) Press Right key three times to blink the of under the CL.
(3) Pressing Up key to turn on.
(4) Measure the voltage between GND and 3
rd
pin on the CN6.
DC voltage is +24V
Æ Cooling fan is defective.
DC voltage is 0V
Æ MMB board is defective.
(5) Replace defective part.
- Ignition application does not work (never dip).
(1) Remove CN8 connector from MMB board.
(2) Press Right key five times to blink the of under the NZ.
(3) Pressing Up key to turn on.
(4) Measure the voltage between GND and 4
th
pin on the CN8.
DC voltage is +24V
Æ Motor for application is defective.
DC voltage is 0V
Æ MMB board is defective.
(5) Replace defective part.
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29
４ Replacement of Spare Parts
・ 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.
・ Warning： Never use consumables, accessories and/or spare parts other
than genuine articles provided by the manufacturer, or products
specified as suitable by the manufacturer.
４.１ Replacement of Control Unit Components
For the parts location, refer to “Appended Fig 1 Control Unit Parts Position”.
Always install a new part in the same orientation as the part that was removed. Also, if wires
have to be disconnected, make sure to reconnect them in the same way as before. (Refer to
"Appended Fig. 3 Control Unit Wiring Diagram”.)
Loosen 4 screws at the bottom on both sides of the control unit (see Fig. 20) and remove the
control unit cover by pulling it upwards.
C
ontr ol Unit Cove
r
Fixing Screw
（
Both Sides
）
Panel Fixing Screw
（
Both Sides
）
Panel
Control Unit Cover
Fig. 20 Control Unit
！
Page 31
30
４.１.１ CPU Board
The CPU board is inserted into a socket in the center of the MAIN board. Check it has been
inserted correctly by using the Connectors No. (CNA and CNB) See Fig. 21.
CPU Board
Connector (CNB)
Connector (CNA)ROM
CPU
Internal Battery
To Control Panel
Front Rear
MAIN Board
RTC
Built-in Clock Board Connector (RTC)
BAROMETER
REF2
Barometric Pressure Sensor Connector
(BAROMETER & REF2)
Fig. 21 MAIN Board
４.１.２ ROM
As shown in
Fig. 21, insert the ROM so that the indentation faces the CNB connector.
４.１.３ Internal Battery
The internal battery is soldered in place. After replacement, re-enter the data of the
“Appended Table 1 APM-7 Setting Table” in accordance with the adjustment method.
４.１.４ Barometric Pressure Sensor (option)
The barometric sensor consists of sensor unit and power supply IC chip. Insert the sensor
unit and IC chip so that the indentations face front side.
４.１.５ Built-in Clock board (option)
As shown in
Fig. 21, insert the built-in clock board so that the indentation faces front side.
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31
４.２ Replacement of Test Unit Components
For the parts location, refer to “Appended Fig. 2 Test Unit Parts Position”.
Always install a new part in the same orientation as the part that was removed. Also, if wires
have to be disconnected, make sure to reconnect them in the same way as before. (Refer to
"Appended Fig. 4 Test Unit Wiring Diagram”.)
For the removing of the covers, refer to Fig. 22. Remove the windscreen first, rear cover next,
then side covers.
Rear Cover
Fixing Screw
Rear Cove
r
(Slide Backward)
S
ide Cove
r
Fixing Screw
S
ide Cove
r
(Slide Up, then
Slide Backward)
Windscr een
Fixing Screw
Windscr een
Windscreen Guide
Arm Cover
Fig. 22 Test Unit
４.２.１ Temperature Sensor
(1) Remove arm cover of the test unit. See
Fig. 23
(2) Remove wires of the temperature sensor from the terminal.
(3) Pull out the temperature sensor from the test cover, then remove ferrule.
(4) Attach new temperature sensor in reverse order.
Side View
Top View
A
rm Cove
r
R
W
R
B
W
Flash Detector
Temperature Sensor
Arm Cover Fi xing Screw
W : White
R : Red
B : Black
Fig. 23 Arm
Page 33
32
４.２.２ Flash Detector
(1) Remove arm cover of the test unit. See Fig. 23
(2) Remove wires of the flash detector from the terminal.
(3) Pull out the flash detector from the test cover, then remove ferrule.
(4) Attach new flash detector in reverse order.
４.２.３ Heater Block
There are three terminal holes in heater block mounting section. The front hole is used for
ground, two back holes are used for the heater.
The guide hole is located by the right side of the ground hole. and preventing bad
orientation setting.
Align the the match mark ( ) on the heater block top plate with the test unit match mark
( ).
Orientation Guide
Ground Terminal
Heater Terminal
Match Mark
Fig. 24 Heater Block Mounting Section
Heater Terminal
Orientation Pin
Heater Support
Heater Fixing Screw
Band Heater
Ground Terminal
Match Mark
Fig. 25 Heater Block
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33
Heater Terminal
Orientation Pin
Heater Support
Band Heater
Ground Terminal
Fig. 26 Heater Block (Reverse Side)
The replacing procedure of band heater (element) is as follows.
(1) Remove wires of heater and ground from their terminals.
(2) Remove heater support.
(3) Loosen two heater fixing screws, then remove band heater.
(4) Attach new heater in reverse order.
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34
４.２.４ Photo Micro Sensor
(1) Remove the arm cover.
(2) Pull out the sensor socket from the photo sensor.
(3) Remove the photo sensor from the arm.
(4) Attach new photo sensor in reverse order.
2 ~ 4 mm
The reflector does not touch the photo sensor
Reflector
Photo Micro Sensor
Socket
Cam for Application
The reflector covers
the photo micro sensor
Motor Shaft
Height Adjuster
Fig. 27 Position of Photo Micro Sensor
４.２.５ Electric Igniter
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.
Terminal for Igniter
Push here when pulling wires
Fig. 28 Electric Igniter Terminal
！
Page 36
35
Next, Loosen knurled screw of pilot/(ignition source) mount, and then pull the electric igniter.
See
Fig. 29.
Arm Cover
Pilot Mount
Flame Nozzle
Insulator
Soldered Part
Dipping Rod
Fig. 29 Pilot Mount
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
４.２.６ Interchange of the Ignition Source (Gas Æ Electric)
Caution: If the fluctuations range of AC voltage is not within 5%, not
only filament may be burnt out in a short time, but also
obtained flash point will be varied when igniter is used as a
ignition source.
Do not use Electric Ignition if AC voltage is unstable.
！
Page 37
36
The ignition source of APM-7 is interchangeable.
The following procedure is described from gas ignition to electric ignition.
(1) Turn the MAIN switch OFF.
(2) Close main gas cock and remove gas hose from the tester.
(3) Loosen knurled screw of ignition source mount, and then pull the test flame nozzle.
(4) Pull out the black rubber tubing with flame nozzle from slanting panel then keep them
for future use.
(5) Loosen clamp of electric igniter wire which is located bottom side of arm.
(6) Loosen knurled screw of pilot mount, and then pull the electric igniter.
(7) Insert electric igniter to the ignition source mount fully with the soldered end of the coil
facing upward, and fix it by tightening the knurled screw.
Insulator
Soldered Part
Set Screw for
Dipping Angle
Knurled Screw
Fig. 30 Attachment of Electric Igniter
(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.
Page 38
37
GE
SW2
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.
Set Screw for
Dipping Angle
Fig. 32 Dipping Angle
Page 39
38
Appended Table 1 APM-7 Setting Table
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.
Initial Heat Cooling Time External Output
First Application
Te mp .
( ) ( ) ( ) ( )
Page 40
39
Display
Panel
Main Switch
Power Supply
Noise Filter
Signal Cable Connector
MAIN Board
CPU Board
Appended Fig. 1 Control Unit Parts Position
MMB Board
Solenoid Valve for Gas
Start Relay
Heater SSR
Power Supply
Appended Fig. 2 Test Unit Parts Position
Page 41
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