Ametek JOFRA ATC-125 User manual

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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List of contents
1.0 General ..................................................................................... 5
1.1 Introduction ................................................................................... 5
1.2 Safety Instructions ........................................................................ 7
1.3 Adjusting and Calibrating the Instrument...................................... 8
2.0 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.............................................. 12
2.1.1.3 Service Output Menu ........................................... 15
2.1.1.4 Service Keyboard Menu ...................................... 16
2.1.1.5 Service Display Menu .......................................... 16
2.2 Trouble Shooting......................................................................... 17
2.2.1 Supplies ............................................................................ 35
2.2.2. Oil Problems ..................................................................... 35
2.3 Replacement of Spare Parts....................................................... 37
2.3.1 DIP-Switch Settings.......................................................... 59
2.3.2 Configuring the Power PCB for ATC-320 A/B (version 1) 60
2.3.3 Configuring the Power PCB for ATC-320 A/B (version 2) 61
2.3.4 Configuring the Power PCB for ATC-650 A/B (version 1) 61
2.4 Adjusting and Testing PCB’s ...................................................... 61
2.4.1 Current limiter for ATC-140/155/156/157 A/B .................. 61
2.4.2 MVI Circuit for ATC-250/320/650 A/B .............................. 62
3.0 Spare Parts and Drawings.................................................... 64
3.1 Spare Parts ................................................................................. 64
3.2 Exploded View – ATC-125 A/B................................................... 73
3.3 Exploded View – ATC-140 A/B................................................... 74
3.4 Exploded View – ATC-155 A/B................................................... 75
3.5 Exploded View – ATC-156 A/B................................................... 76
3.6 Exploded View – ATC-157 A/B................................................... 77
3.7 Exploded View – ATC-250 A/B................................................... 78
3.8 Exploded View – ATC-320/650 A/B............................................ 79
3.9 Wiring Diagram – ATC-125 A ..................................................... 80

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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 – ATC-157 A ..................................................... 86
3.16 Wiring Diagram – ATC-157 B ..................................................... 87
3.17 Wiring Diagram – ATC-250/320/650 A ....................................... 88
3.18 Wiring Diagram – ATC-250/320/650 B ....................................... 89

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1.0 General
1.1 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.
Each calibrator passes several tests during assembly. It undergoes a
final inspection and test, followed by a special calibration procedure
laid down by our technical staff.
Caution…
If you decide to check and/or re-calibrate the calibrator, you
must always use certified test equipment only and ensure
proper contact between the test probe and the well of the
calibrator.
Operating guidelines and technical specifications are outlined in
reference manual order no. 105446. Please note that this is only
available in English.

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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.
Note…
Please note that we would be very interested in hearing
from you if you have any ideas or suggestions for changes
to our products.
AMETEK Denmark A/S
Gydevang 32- 34
3450 Allerød
Denmark
Phone: [phone]
Fax: [phone]

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1.2 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.
For a more detailed description of the safety instructions
we refer to the reference manual 105446 or the user
manual 105447.
Safety Symbols
This manual contains a number of safety symbols designed to draw
your attention to instructions that must be followed when using the
instrument, as well as any risks involved.
Warning
Events that may compromise the safe use of the instrument
and result in considerable personal or material damage.
Caution…
Events that may compromise the safe use of the instrument
and result in slight personal or material damage.
Note…
Special situations which demand the user’s attention.

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1.3 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.

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2.0 Repairs
Warning
The calibrator must be switched off before any attempt is
made to service the instrument.
Note…
If the software detects an error during operation, the error
will be shown in the display.
Make a note of the error message and contact your
distributor or AMETEK Denmark’s Service Department.
AMETEK Denmark’s liability ceases if:
• parts are replaced/repaired using spare parts, which are
not identical to those recommended by the manufacturer.
• 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.
2.1 Service Menu
In the Service Menu it is possible to check a number of conditions in
the equipment. To reach the Service Menu, follow the procedure
described on the following pages:

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)
T
urn the equipment on while pressing the and button.
T
he 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. Likewise, Work Orders cannot be executed.
2.1.1 Service Main Menu
)Press and the Service Menu will appear
Following information can be seen
• Mains freq shows mains frequency, which is measured by the
ATC itself. This has to comply with the actual mains frequency
(50Hz or 60 Hz)
• Tick is a counter with 1ms increment that starts when the
instrument is turned on.

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• 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 PC,which
has set up the ATC.
• Day No. registers the number of days that the instrument has
been switched on.
2.1.1.1 Service Power Menu
)Press in the Service Menu and the Service Power Menu
will appear.
The information has been listed in 2 columns, relating to the primary
regulator and the differential regulator (Slave), respectively. The slave
readout shows the activity in the top zone. (ATC-155 does not have a
top zone).
• PID SET temp. tells which temperature the calibrator is set to
(even if it is not activated) (“Slave” is always set to 0)
• PID READ temp. explains the readout of the regulating sensor in
°C.
• Power setting informs about the regulation percentage in the two
PID regulators.
• NewToff, TriacTp, TriacDeltaT are calculated time for the
Triac’s. These variables are set to zero on the cooling calibrators.
• DutyK is a variable compensation for alternating mains voltage.
At nominal mains voltage (230V or 115V) this is approx. 1.00
• Heat/cool explains whether the regulation is heating or cooling.

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• 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. The first column shows values as electrical units and
the other column the corresponding values in °C.
Next to Cold Junctions also a converted mV value is displayed. This
value is the voltage the chosen thermocouple type has to be
compensated with.
)Press in the Input Menu and the regulating AD-
converters Menu will appear.
Shown here are the A/D-converted values for the regulating sensors.
The displayed values are typical values.

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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.
Ref 1 must have a value between 15.000.000 and 16.700.000. If the
value is 16.777.215 or is below 15.000.000, there is an error in the
circuit.
Cold junc. will have a value, which is depending on the temperature
in the instrument. The value may vary between 10.500.000 and
12.000.000. 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,
placed in the thermocouple connector on the front panel.
Diff. TC has to be between 8.300.000 and 8.500.000, when the
calibrator is stable.
)Press in the Service Input Menu and the Reference
sensor AD-converter Menu will appear.
Shown here are the A/D-converted values for the measurements on
the external reference. The shown values are typical values.
RTD, RTD off, R2, R2 off, R3 and R3 off.
RTD off, R2 off, R3 and R3 off have to be between 8.300.000 and
8.500.000.

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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. If the
value is 16.777.215 or below 15.000.000, there is an error in the
circuit.
)Press in the Service Input Menu and the Sensor input
AD-converter Menu will appear.
Shown here are the A/D-converted values for the measurements on
the SENSOR inputs.
The shown values are typical values. The values are only updated for
the inputs that are active.
The values for RTD and RTD ref. apply, when a Pt100 has been
chosen as sensor.
TC must have a value between 8.300.000 and 8.500.000, when the
input is short-circuited.
RTD must have a value between 10.000.000 and 11.000.000, when a
100-ohm resistance is connected to the input.
RTD ref must have a value between 15.000.000 and 16.700.000.
The values for RTD and RTD ref. apply, when a Pt100 has been
chosen as sensor.
mA must have a value between 32.000 and 33.500, when the inputs
are open. At 20mA the value must be between 58.000 and 61.000.

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Vmust 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
appear.
Here it is possible to test whether the beeper works and whether the
Sync. relay can change.

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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 %.
Also, it is possible to show various pictures to test the display.
For further information about operation of display see user manual
105447, section 3.12.

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2.2 Trouble Shooting
Error code: 10
Error message: Display called recursively
Likely cause: Solution:
Internal software error Please report error to AMETEK Denmark
A/S.
Error code: 11
Error message: Display structure no. illegal
Likely cause: Solution:
Internal software error Please report error to AMETEK Denmark
A/S.
Error code: 21
Error message: Display array index illegal
Likely cause: Solution:
Internal software error Please report error to AMETEK Denmark
A/S.
Error code: 22
Error message: Display array called recursively
Likely cause: Solution:
Internal software error Please report error to AMETEK Denmark
A/S.

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Error code: 23
Error message: Display array structure No. illegal
Likely cause: Solution:
Internal software error Please report error to AMETEK Denmark
A/S.
Error code: 24
Error message: Display array index mismatch
Likely cause: Solution:
Internal software error Please report error to AMETEK Denmark
A/S.
Error code: 25
Error message: Variable type illegal
Likely cause: Solution:
Internal software error Please report error to AMETEK Denmark
A/S.
Error code: 30
Error message: Negative array index
Likely cause: Solution:
Internal software error Please report error to AMETEK Denmark
A/S.
Error code: 50
Error message: Too many edit fields
Likely cause: Solution:
Internal software error Please report error to AMETEK Denmark
A/S.

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Error code: 60
Error message: Too many slow data fields
Likely cause: Solution:
Internal software error Please report error to AMETEK Denmark
A/S.
Error code: 61
Error message: Too many fast data fields
Likely cause: Solution:
Internal software error Please report error to AMETEK Denmark
A/S.
Error code: 70
Error message: Too many listbox lines
Likely cause: Solution:
Internal software error Please report error to AMETEK Denmark
A/S.
Error code: 80
Error message: Message on message not allowed
Likely cause: Solution:
Internal software error Please report error to AMETEK Denmark
A/S.
Error code: 81
Error message: No message to remove
Likely cause: Solution:
Internal software error Please report error to AMETEK Denmark
A/S.

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Error code: 100
Error message: Calibrator type illegal
Likely cause: Solution:
Wrong calibrator type
setting
Check that calibrator setting is correct on
Main PCB (see section 2.3.1 on DIP Switch
Setting)
Error code: 200
Error message: MenuLevel too high
Likely cause: Solution:
Internal software error Please report error to AMETEK Denmark
A/S.
Error code: 300
Error message: AD-converter not responding
Likely cause: Solution:
Error in communication
with one of the A/D-
converters
Check that all voltages on the power PCB
are correct. If they are, the Main PCB is
defective. Replace the Main PCB.
If not, replace Power PCB.
Error code: 310
Error message: Slave temperature too high
Likely cause: Solution:
When main adjustment
has become stable,
differential temperature
between top and bottom
is still outside the limits.
Check measuring circuit with a short circuit
in the differential TC connection (CN16 on
input board) instead of the sensors. Check
in Service Input Menu that Slave TC shows
0°C±0.1°C. If this is OK, there is an error on
the sensor. Otherwise, there is an error on
the Main PCB.