JOBO ATL 1500 Operator's manual

JOBO Labortechnik GmbH + Co. KG
KölnerStr.58
D-51645 Gummersbach (Derschlag) Made in Germany Technical modifications are reserved 09097
Service-Documentation ATL-1500
Table of Contents:
GeneralAssembly
Topic Chapter
General Assembly 1
Removing the inner casing 1.1
Opening the unit 1.2
Closing the unit 1.3
Disassembling the control panel 1.4
Servicing the housing cover 2
Disassembling the cover 2.1
Disassembling the cover closure 2.2
Closure adjustment 2.3
Disassembling the cover panel 2.4
Servicing the chemistry bottles 3
Exchanging the bottles 3.1
Exchanging the bottle lid panel 3.2
Servicing the circulation pump 4
Exchanging the pump 4.1
Exchanging the temperature sensor 5
Disassembling the temperature limiter 6
Replacing the chemistry hoses 7
Removing the chemistry hoses 7.1
Installing the new chemistry hose 7.2
Exchanging the heater 8
Servicing the float 9
Exchanging the sensors 10
Replacing the level sensors 10.1
Exchanging the upper lift arm sensor 10.2
Exchanging the lower lift arm sensor 10.3
Exchanging the air distributor sensor 10.4
Exchanging the cover sensor 10.5

JOBO Labortechnik GmbH + Co. KG
KölnerStr.58
D-51645 Gummersbach (Derschlag) Made in Germany Technical modifications are reserved 09097
Service-Documentation ATL-1500
Table of Contents:
GeneralAssembly
Topic Chapter
Servicing the motors 11
Disassembling the lift arm motor 11.1
Disassembling the drive motor 11.2
Disassembling the air distributor motor 11.3
Servicing the base 12
Disassembling the air distributor 12.1
Chemistry router 12.2
Membrane pump 12.3
Drain valve 12.4
Disassembling the gas-loaded spring 13
Servicing the lift arm 14
Disassembling the lift arm 14.1
Replacing the gears with lift arm removed 14.2
Servicing the control panel 15
Replacing the EPROM 15.1
Exchanging the power switch 15.2
Disassembling switch and display PC-board 15.2.1
Disassembling the main PC-board 15.3

JOBO Labortechnik GmbH + Co. KG
KölnerStr.58
D-51645 Gummersbach (Derschlag) Made in Germany Technical modifications are reserved 09097
Service-Documentation ATL-1500
1.2 Opening the unit
1.2.1 Empty the unit (see BA page 34, section 12.5)
1.2.2 Pull out drain valve knob
1.2.3 Remove Phillips screws from base
Assembly advice: The drain valve knob must positively
lock when pushed in (snapping sound)
1. GENERAL ASSEMBLY
1.1 Removing the inner casing
1.1.1 Remove mounting screws with Phillips screw
driver and pull out drain valve
1.2.4 Tilt top of unit forward
1.3 Closing the unit
1.3.1 Before closing the unit, guide connecting pipe for
drain valve into opening

JOBO Labortechnik GmbH + Co. KG
KölnerStr.58
D-51645 Gummersbach (Derschlag) Made in Germany Technical modifications are reserved 09097
Service-Documentation ATL-1500
1.4 Disassembling the control panel (95436)
1.4.1 Open unit cover
1.4.2 Loosen marked screws
Carefully lift and turn around control head housing.
2.1 Disassembling the cover
First disengage gas-loaded spring then disassemble
housing cover.
2.2 Disassembling the cover closure
Remove screws on inside of lid and lift out cover
closure.
2. SERVICING THE HOUSING COVER
2.3 Closure adjustment
Loosen lock nut, turn closure pin until distance to hex
nut approximates 3 thread turns. Check closing
performance.
Housing cover must press down all bottle lids.
2.4 Disassembling the cover panel
2.4.1 Disengage cover panel
3. SERVICING THE CHEMISTRY
BOTTLES
3.1 Exchanging the bottles
Remove inner casing as explained in section 1.1. Pull
out bottle temperature sensor and remove bottle.
3.2 Exchanging the bottle lid panel
Remove inner casing according to section 1.1 of
service documentation.
- Remove screw.
- Pull fastening ring apart.
- During assembly, the fastening ring must lock in
place at bottle neck.

JOBO Labortechnik GmbH + Co. KG
KölnerStr.58
D-51645 Gummersbach (Derschlag) Made in Germany Technical modifications are reserved 09097
Service-Documentation ATL-1500
Water
4. SERVICING THE CIRCULATION PUMP
4.1 Exchanging the pump
- Disassemble inner casing.
- Pull bottle temperature sensor out of bottle (Careful!
Temperature sensor is made of glass. Danger of
breakage!)
- Remove bottles 1 through 4
- Disengage submersion pump from mounting bracket
- Cut tie wrap.
Disassemble control panel. (according section 1.1
of service documentation)
- Cut connecting cord at grommet.
- Exchange pump.
- Attach new cord with clamping pliers or solder.
Attention: Do not confuse cords! + -
Assembly in reverse sequence.
5. EXCHANGING THE TEMPERATURE
SENSOR
- Open unit.
- Pull connector off main PC-board.
- Disassemble control panel (according section 1.4.)
- Pull cord out of opening.
Assembly in reverse sequence.
Advice: Seal cord opening with additional silicon.
Pump
6. DISASSEMBLING THE
TEMPERATURE LIMITER
Remove inner casing and disassemble control panel.
Pull bottle sensor out of bottle and remove bottles.
Cut tie wrap, loosen holding bracket of heater and
detach temperature limiter from heater. Remove
mounting screw of temperature limiter.
Pull off connectors. Pull limiter out of grommet.
Assembly in reverse sequence.
Advice: Seal cord opening with additional silicon.
7. REPLACING THE CHEMISTRY HOSES
Remove unit cover and inner casing.
7.1 Removing the chemistry hoses
Pull chemistry hose off bottle and hose collector.
7.2 Installing the new chemistry hose
Glue new hose with 'Sekunden-glue' to hose collector
and seal with silicon.
Hose position according to illustration.

JOBO Labortechnik GmbH + Co. KG
KölnerStr.58
D-51645 Gummersbach (Derschlag) Made in Germany Technical modifications are reserved 09097
Service-Documentation ATL-1500
1. 2.
Upper lift arm sensor
Sensor
9. SERVICING THE FLOAT
The mounting screw must not be over-tightened in
order to assure smooth operation.
10. EXCHANGING THE SENSORS
10.1 Replacing the level sensors
- Disassemble control unit
- Pull push-on connectors off main PC-board.
- Remove sensor.
10.3 Exchanging the lower lift arm sensor
Open unit as explained in section 1.2.
- Pull sensor out of mounting bracket and cut wire.
- Attach new sensor with silicon
Solder connections and insulate solder point.
8. EXCHANGING THE HEATER
Disassemble inner casing and control panel.
Pull bottle temperature sensor out of bottle and
remove bottle. Disengage holding spring for heater
and temperature limiter from heater. Apply pull to
power cord and loosen mounting nuts with ratchet
(7mm). Lift heater at its left corner and pull out of
housing.
Assembly in reverse sequence.
Level sensor
10.2 Exchanging the upper lift arm sensor
Remove inner casing.
- Remove sensor
- Cut wire
- Attach new sensor with silicon
- Solder connections and insulate solder point.

JOBO Labortechnik GmbH + Co. KG
KölnerStr.58
D-51645 Gummersbach (Derschlag) Made in Germany Technical modifications are reserved 09097
Service-Documentation ATL-1500
Gear segment
11.3. Disassembling the air distributor motor
- Open unit (see section 1.2.)
- Disengage linkage at chemistry router. Then remove
4 socket screws of air distributor.
- Cut wire harness tie wraps. Remove 4 slotted-head
screws and pull off push-on connectors.
Assembly in reverse sequence.
Attention: Make sure chemistry router operates smoothly!
10.4 Exchanging the air distributor sensor
Open unit
- Remove sensor at air distributor, cut wire.
- Attach new sensor, solder wire and insulate solder
point.
10.5 Exchanging the lid sensor
Disassemble control panel.
Disassemble switch PC-board and display PC-board
as explained in section 10.2. Remove sensor.
Desolder wire.
11. SERVICING THE MOTORS
11.1. Disassembling the lift arm motor
Remove inner casing
- Remove bottles 5 and 6 and cover foil from under
hose collector.
- Disassemble gear segment.
- Unscrew mounting screws (1 socket screw / 1
slotted-head screw below Allen screw) and open
housing.
- Open cover panel, pull out drive sprocket and motor
simultaneously .
- Pull of push-on connectors.
- Note connector position at motor:
connector 1: orange
connector 2: brown
- Insert new motor and mount with screws.
Assembly in reverse sequence.
11.2 Detaching the drive motor
Remove inner casing.
- Disassemble gear segment. Loosen 4 screws of lift
arm and remove lift arm.
Open unit
- Loosen 2 mounting screws of motor and remove
motor.
Mounting screws for drive motor
Lift arm
motor

JOBO Labortechnik GmbH + Co. KG
KölnerStr.58
D-51645 Gummersbach (Derschlag) Made in Germany Technical modifications are reserved 09097
Service-Documentation ATL-1500
- Push hoses all the way up and seal with silicon.
- Attach drain valve with tie wrap to base.
13. DISASSEMBLING THE GAS-LOADED
SPRING
Open unit
- Remove splash guard foil from side wall.
- Loosen mounting strip for gas-loaded spring at base.
- Disengage gas-loaded spring at cover, remove
housing lid according section 2.1.
- Unscrew gas-loaded spring out of mounting blade
and pull downward out of housing.
Assembly in reverse sequenceService Documentation
12.4 Drain valve
Note mounting direction
12. SERVICING THE BASE
12.1 Disassembling the air distributor
Remove inner casing.
- Pull air hoses out of bottles and pull off hose
connector elbows.
- Open unit.
- Remove 4 socket screws at air distributor and
disengage linkage of chemistry router.
- Pull air hoses out of unit top, loosen push connector.
- Be careful to route main air hose to membrane
pump under guide bar!
12.2 Chemistry router
Assembly advice: Be careful to route main air hose
to membrane pump under
guide bar!
12.2.1 Tighten screws of linkage only firm enough to
allow for full movement!
12.2.2 Position of curve plate at air distributor
- Zero position (magnet at zero sensor)
12.3. Membrane pump
Assembly advice:
Connection positions: red +white -
Attachment of air hose as explained in section 12.1.
Note connector positions:
Attention: Protect base from residual water
draining from pump when
disassembling.
Valve position
Position of Drain
valve knob

JOBO Labortechnik GmbH + Co. KG
KölnerStr.58
D-51645 Gummersbach (Derschlag) Made in Germany Technical modifications are reserved 09097
Service-Documentation ATL-1500
14. SERVICING THE LIFT ARM
14.1 Disassembling the lift arm
Remove inner casing.
Remove gear segment. Remove 4 Phillips screws
from lift arm. The lift arm can now be easily removed.
14.2 Replacing the gears with lift arm removed
Disassemble mounting clamps.
- Loosen Phillips screw at transfer sprocket and pull
out sprocket toward front.
- Pull out square shaft with pliers.
15. SERVICING THE CONTROL PANEL
15.1 Replacing the EPROM
Refer to insert sheet for EPROM 94069
15.2 Exchanging the power switch
- Pull off connections and control foil
- Push switch out
15.2.1 Disassembling switch and display PC-board
- Pull off control buttons.
- Push spacers of BCD-switches outward and pull out
- Loosen Phillips screws at PC-boards, lift PC-boards
and carefully pull out of housing.
15.3 Disassembling the main PC-board
Open unit
- Loosen (5) socket screws at PC-board
- Pull off connectors
- Remove PC-board

Servicemenue ATL 1500
1. Start of service test
•Set BCD-Switch in position 16
•Press PLUS and ENTER-Key simultaneously and the switch unit on (SET DEF
mode = setting of default values).
•Simulate a closed cover by putting a magnet to the sensor on the left side of the
control unit.
•Press PLUS-Key. Display now shows: ---
2. Drum motor and filling pump test
•Set BCD-Switch in position 1. Display shows: FPS
•Press PLUS-Key for switching motor one step forward. Sound of working motor
should now be heard.
•Press ENTER-Key for turning on the pump - green LED “TWA” is on.
•Press ENTER-Key again for turning the pump off.
3. Lift arm test
•Set BCD-Switch in position 2. Display shows: Li
•Press PLUS-Key. Liftarm know has to move up, green LED is on
•Press ENTER-Key. Liftarm will move down, green LED is off.
Attention: This check is only possible, if the cover is closed or a magnet is put to the
sensor.
4. Magnet valve test
•Set BCD-Switch in position 3. Display shows: UA
•Press ENTER-Key magnet valve will open and fill up the unit, green LED is on.
•Press ENTER-Key again magnet valve will close, green LED is off.
•Press PLUS-Key magnet valve will open and closes automatically after 10
seconds
5. Temperature Test
•Set BCD-Switch in position 5 Display shows 38ºC
•Press PLUS-Key, green Led is on heating period starts
•If temperature is reached an acoustic signal is given an de display shows END
Attention: This test can only be made if the first bottle and the water jacket is filled
with water
6. Eeprom Test
•Set BCD-Switch in position 6. Display shows: E2P

•Press PLUS-Key for test start. After successful termination of the test green LED
“TWA” is on. If the test runs with an error the LED is off.
Attention: During test execution all data in Eeprom will be erased and default data
will be wrote into Eeprom.
7. Test program
•Set BCD-switch in position 7. Display shows: PRO
•Press ENTER-Key. Test process will be started with following steps.
•Heating 24ºC
•Pre Cleaning (30s)
•Chemical 1 (30s)
•Cleaning 1 (30s)
•END
8. Cleaning test program
•Set BCD-switch in position 8. Display shows: FIL
•All bottles have to be filled with water
•Press ENTER-Key and close the cover
•After finishing the program display shows END