Tanaka ASP-5 User manual

Automated Softening Point Tester
Model ASP-5
Maintenance Manual
Ver.1.10 070913
Read this manual thoroughly before using the product,
and store in a safe place for future reference.
TANAKA SCIENTIFIC LTD, TOKYO, JAPAN

1
Contents
1．Setting Changes······································································································2
1.1 Heater Output Flow·························································································4
1.2 Constants Setting Screen ···············································································4
1.2.1 Setting the temperature rise rate·································································4
1.2.2 Setting the measuring range·······································································5
1.1.3 Setting the test conditions···········································································5
1.2.4 Setting the external connections·································································6
1.3 Temperature Unit Selection and Temperature Correction·································7
1.4 Date and Time Setting····················································································10
1.5 Constants Printing ··························································································10
2. I/O Check················································································································· 11
3. Adjustment···············································································································12
3.1 Ring Holder Adjustment··················································································12
4. Faults and Countermeasures···················································································13
4.1 Fault Displays and Countermeasures·····························································13
4.2 Unit Faults and Countermeasures··································································16
5. Parts Replacements·································································································18
5.1 Control Unit Parts Replacements····································································18
(1) Replacing the CPU··················································································18
(2) Replacing the ROM·················································································18
(3) Replacing the fluorescent display····························································19
(4) Replacing the power supply ····································································20
5.2 Measuring Unit Parts Replacements ······························································20
(1) Replacing the projection lamp·································································20
(2) Replacing the light receiver board···························································20
(3) Replacing the heater···············································································21
(4) Replacing the cooling fan········································································21

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1. Changing Settings
The switches on the front of the control unit can be used to change settings. While holding
down the RESET key, press the FUNCTION key. Then release only the RESET key to
display the menu shown in Fig.1. Select the necessary menu item by using the right/left keys
to move the cursor, and press the FUNCTION key to confirm the selection.
The screen in Fig. 2 is displayed when "Para set" is selected and the FUNCTION key
pressed to confirm the selection.
When the FUNCTION key is pressed after adjusting settings, the cursor automatically
moves to "End". Keep pressing the FUNCTION key to return to the original screen.
After returning to the main screen shown in Fig. 1, press the RESET key to return to the
Menu screen.
Be sure to record any changes to setting numeric values.
This record will be needed when the battery for the RAM goes flat (about 5 to 7 years).
Ver 1.0
Paraset Tempcal
Time set
Para Prt
Fig.1 Menu Screen
Rate Range Test.para
Output End
Fig.2 Parameter Settings Screen

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Rate Bath liquid, initial heating, base, limiter,
auto start temperature, temperature rise rate,
and PID settings
Range Mode, bath liquid, one-sided test, safety
stop temperature, and upper and lower
measuring temperature limits
Para set Test.para Detection rate, additional mode, and
result rounding
Output Connected equipment, equipment number,
End test number, detailed printing, and sample name
Water bath C/F Temperature correction in water bath
Temp cal Glycerin bath C/F selection Temperature correction in glycerin
bath
End
Time set Sets the internal clock (option)
Para Prt Prints the settings (only applicable when a printer is
connected)
From the standard main screen, the following screens can be displayed by key operations:
Test results This screen displays up to 20 test results.
Press the RESET and MODE keys together, then
release the RESET key first.
I/O check This screen is used to check tester I/O.
Press the RESET key together with the up key and
down key and release the RESET key first.
Fig. 3 Details of the Settings Screen

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1.1 Heater Output Flow
· Start: The initial heat is calculated and output (base heater + initial heater).
· 1 min (water), 2 min (glycerin) later: The initial heater is turned off for the base heater
and bias heater output.
· Auto start temperature: Auto control starts when the temperature rise rate has reached
5°C/min.
Until then, the above heater output remains ON.
· Auto control start: The heater output is calculated from the PID constant.
The heater output limit is calculated and the heater output (base heater + bias heater)
is limited. Then the result is output.
1.2 Constant Setting Screen
1.2.1 Heating settings
For the two different kinds of bath liquid (water and glycerin), the following values can
be set:
Liquid Init Base Limit Auto
Water 15% 50% 00% 005°C
Rise rate P ID
5.0°C/min 50 04 60 End
Fig.4 Heating Settings Screen
· Liquid Set the bath liquid type (water or glycerin) used in the test.
· Init Heater output 1 min (water) or 2min (glycerin) after the start of a
test.
· Base Heater output during a test.
· Limit Calculated output of the base and bias heaters in the setting
range.
· Auto Temperature at which to start automatic heating control. Auto
control starts if the heating rate exceeds the set value (5.0°C/min
in the above example) at this or higher temperatures.
· Rise rate Temperature rise per minute (only 5.0°C/min preset)
Except when the rate is 5.0°C/min, set the necessary items
again.
· P,I,D Calculation parameters for auto heating rate adjustment.

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1.2.2 Measuring range settings
For two or four modes, the following items can be set:
Mode Liquid 1-sample Cut temp
0Water off 15°C
Range_H Range_L
080°C020°CEnd
Fig.5 Measuring Range Setting Screen
· Mode Selects the mode that is displayed on the ordinary main screen.
The tester has two standard modes, water and glycerin. However,
two additional modes can be added by setting "Add mode" in "Test
parameters" to “Yes”.
For example, tests that end with one-sided drop detection can be
set as an additional mode.
· Liquid Specify the bath liquid for use in the mode (water or glycerin).
When this is specified, tests are performed using the settings from
the heating settings screen.
· 1-sample Usually set to off.
When Yes is specified, testing ends after the detection of a
one-sided drop.
· Cut temp Temperature of safety stop after one-side drop detection (Usually,
+10°C)
By default, a test ends about two minutes after one-side drop
detection. Change the setting when measuring samples of very
different softening points simultaneously.
· Range_H Usually set to 80°C for the water bath and 150°C for the glycerin
bath.
· Range_L Usually set to 20°C for the water bath and 75°C for the glycerin bath.
1.2.3 Test parameter settings
Drop conditions, test modes, and test result processing can be modified as follows:
Det. sens Add.menu Rounding
85% Off On
End
Fig.6 Heating Settings Screen

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· Det.sens The default is 85%. A drop is detected when the receiver input level has
dropped to "Average detector input over preceding 10 to 20 seconds
×Detection sensitivity ÷100".
During a test, check the status on the secondary display (press the
CHECK key). (See Fig.7)
Status Projector output Receiving Level (L-R)
MEAS P_OUT RATE RECLEVEL
00% 0.0°C50% 49%
00% 25.0°C35%34%
H_OUT TEMP DETLEVEL
Heater output Sample drop detection level
Fig. 7 Sub Screen
· Add.nenu Two additional test modes can be added to the original two test
modes.
To complete testing a sample, select On here and also at "1-sample"
On the measuring range setting screen.
In addition, the safety stop temperature can be changed.
· Rounding Usually set to On. Rounds the average test result to the nearest
0.5°C.
1.2.4 External connection settings
Printer, PC, and other external connections can be set as follows:
Ext.out Inst No. Test No.
Computer 01 0001
Opt.prt Sample ID
Off Off End
Fig. 8 External Out Settings Screen
Secondary
display

7
· Ext.out "Computer" in default.
Select either "Printer" or "Computer" to specify the equipment
connected to the RS-232C port.
· InstNo. Low-order two digits of the serial number of the Test unit. This can be
used as an identification number for external connections.
· Test No. Counter from 0000 to 9999, incremented by one at the end of each
test
· Opt.prt Usually set Off. If a printer is connected, this setting enables the
heating rate and other data to be printed after a test.
· Sample ID Usually set Off. This setting enables sample name input for each test.
The sample name can be added to the printer and test results.

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1.3 Temperature Unit Selection and Temperature Correction
The temperature correction screen is used to make any corrections if there are any
differences between the temperature display and the softening point thermometer.
The tester handles two kinds of bath liquid (water and glycerin). Compare the temperature
sensor (displayed temperature) of the tester and the softening point thermometer while
using the necessary bath liquid in advance to check the differences.
1.3.1 Procedure of Calibration
Insert the thermometer suitable for the selected liquid bath into the specified hole in the ring
stage and secure it with an elastic band or wire at the standard position. After checking that
the temperature sensor is also at the specified position, place a beaker containing the bath
liquid at the specified position of the measuring unit, put the ring holder in the beaker, and
attach the beaker to the ring holder.
Select the bath liquid using the MODE key and start a test. Compare and record the
thermometer reading and temperature display every 10°C. (Copy the attached settings table
for recording data during this operation.)
Repeat the above operation twice and pigeonhole data as references for correction.
1.3.2 Select Bath Medium and Temperature Unit.
Select Temp Cal from Menu screen, Fig 9 appears first. Select Water or Glycerin (blinks)、
then press FUNCTION key. Fig.10 appears by this operation. Push Right or Left key to blink
“°C”, and then change it by Up or Down key. If you want to go Temperature offset entering
screen, select Next, if you want to finish, select End and then push FUNCTION key.
Fig.9 Bath Liquid Selection Screen Fig.10 Bath Liquid Selection Screen
Correct differences at each correction point, which are at every 20°C from 0 to 200°C on the
following temperature correction screen for each bath liquid:
Example Correction when the 40°C reading is 0.5°C lower than the
thermometer reading
In Fig. 10, the current temperature correction value for 40°C is −1.0°C and the
necessary correction value is +0.5°C.
New correction value =-1.0°C+0.5°C=-0.5°C→-0.5 for 40°C
Bath select
Water Glycerin End
Set temp unit End
°CNext

9
(Water) Next
Temp Pos 0 20 40
Offset +0.0 +0.5 +1.5 -1.0
End
Addition to 40°C
Bath liquid Addition to the total measuring temperature area
Displayed temperature
Correction points are
interpolated linearly.
0°C20°C40°C
Measured temperature
Fig. 10 Temperature Correction (Water bath)
To display the next correction screen, move the cursor using the right/left keys and press the
FUNCTION key.
When the cursor is at a correction value, pressing the FUNCTION key moves the cursor to
the End position. Press the FUNCTION key again to return to the initial temperature
correction screen. From this screen, press the RESET key to return to the standard main
screen, or select End and press the FUNCTION key to return to the main settings screen.
0.5°C
21.5°C
39.0°C

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1.4 Date and Time Settings (Optional)
If a clock board is included with the unit, date and time are set prior to shipping.
When necessary, the date and time can be adjusted as follows:
FUNC key →Set End
Set Value 02 12/16 14: 39
DateTime 02 12/16 15: 30 05
Fig.11 Date and Time Settings Screen
After moving the cursor to the position to be updated using the right/left keys, press the
FUNCTION key to update the selected Date Time field.
When finished, move the cursor to End and press the FUNCTION key to return to the
previous screen, or press the RESET key to return to the standard main screen.
1.5 Printing Settings (Option)
If an optional printer is connected, settings are printed.
If an optional printer is not connected, nothing happens.
(If a PC is connected and "Printer" is set on the external connection setting screen, the
settings can be saved as a file using "Hyper terminal" or other communication software.
Example Baud Rate 9600 bps(for optional printer)
Parity Even
Data bit 7 bits
For the RS-232C connection cable and other details, refer to the Communication Interface
(RS-232C) Manual.

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2. I/O Check
From the standard main screen, press the up key and down key and RESET key together,
then release the RESET key to display the I/O check screen.
Move the cursor to a setting using the right/left keys, change the setting to ON or OFF using
the up/down keys, and check individual I/O equipment.
Ex. : Heater output check
Set RL (relay) to ON and also SSR to ON. If the output is normal, the heater
monitor LED on the front of the measuring unit lights.
After the check, be sure to set RL and SSR to OFF and press the RESET key to
return to the standard main screen.
OUT RL SSR FAN BZ LAMP
Off Off Off Off On B0
IN Poserr Temp Photo→L R
Off 25.3 52 50
Fig. 12 I/O Check Screen
· OUT RL Start relay
Heater circuit safety relay. The heater SSR operates only
when this relay is ON.
SSR Heater SSR
Solid state relay for heater output ON/OFF
FAN Cooling fan
Heater cooling fan
BZ Optional external buzzer (Test end)
Optional DC24V external buzzer
LAMP Projection lamp for drop detection
When the lamp is turned ON, the light quantity is
automatically adjusted.

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· IN Pos err Optional
Enabled when the sensor position detection function is
added
Temp Sensing temperature of temperature sensor
Photo→L R Left and right receiver input levels. When LAMP is set
to ON, the input levels are automatically adjusted to
about 50%.
3. Adjustment
3.1 Ring Stage Adjustment
To avoid detection errors, inspect the position of the ring stage periodically. If mounting nuts
are loose, check the mounting dimensions of the sample shelf and bottom plate. Adjust the
dimensions shown in Fig. 13 and tighten the nuts.
From the top of the ring holder
tothelowerfaceofthetopplate
: 100+/-0.1mm
100
From the lower face of the
Ring holder to the upper face
ofthebottomplate:30+/-0.1mm
30
Fig. 13 Dimensions of the Ring Holder
According to ASTM D36, the bottom of the shouldered rings in the ring holder shall be 25
mm above the upper surface of the bottom plate. ASP-5 is using photoelectric detection
system. If the light beam is passed just above the bottom plate, reflected beam from the
bottom plate disturb the correct detection. The axis of light beam of ASP-5 is passing 5 mm
above the upper surface of the bottom plate. So, ASP-5 detects ball falls 25 mm below the
bottom of the shouldered rings.

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4. Faults and Countermeasures
4.1. Error Messages and Countermeasures
TROUBLE
TEMP SENSOR
Temp [°C] 410.8
Fig. 14 Temperature Sensor Fault Screen
The temperature sensor (PT-100) has an open circuit. Replace the temperature sensor.
(Replace the sensor at the three-pin connector on the upper left of the measuring unit.)
TROUBLE
PHOTO SENSOR LAMP
Temp [°C] 24.9
Fig. 15 Projector Lamp Fault Screen
Lamp output is not reaching either the right or left light detectors. Check that lamp output is
normal and reaching the light detectors.
When the START key is pressed, the intensity of light is automatically adjusted. If the lamp
does not light, replace the lamp.
TROUBLE
PHOTO SENSOR RIGHT
Temp [°C] 24.9
Fig. 16 Light Receiver (Right) Fault Screen
The right light detector of the optical system is not correctly detecting light.
When the START switch is pressed, the optical system is reported as being adjusted on the
right side of the standard main screen. Check that level of light detected changes. If the
intensity of light detected does not change, replace the light detector.

14
Fig. 17 Light Detector Check
TROUBLE
REPLACE BATTERY
Temp [°C] 24.9
Fig. 18 Battery Running Out Screen
The internal settings backup battery is running out. Replace the battery.
TROUBLE
SENSOR POSITION
Temp [°C] 24.9
Fig. 19 Sensor Position Incorrect Screen
Tests are stopped in about 10 minutes if started without the temperature sensor in place or if
the heater has an open circuit.
Check that the temperature sensor is in place, and that the heater is functioning.
(To check heater output, check the heater current indicator lamp on the measuring unit after
starting a test.)
Light Receiver Cover Light Receiver
Assembly
Slit
Diode Array exposed to light

15
TROUBLE
S . P > 80.0
Temp. [°C] 80.2
Fig. 20 Softening Point Detection Failure Screen
The above message is displayed if the sample does not drop within the measuring range.
In this case, press the RESET key and then the FUNCTION key to check the measuring
range on the sub screen.
Circumstances that caused the test to end can be found on this display:
· Beyond the measuring range
· Absolute stop temperature (water bath: 90°C, glycerin bath: 200°C)

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4.2. Unit Faults and Countermeasures
Table 1 Control Unit Troubleshooting
Problem Things to check Countermeasure
Nothing is
displayed.
Cannot start, protector activated
Cannot start, protector did not activate
Can start, display faulty
Check short circuit of
heater
Replace power supply.
Replace the display.
The display is not
accurate.
Can start
Cannot start
Replace display module.
Replace the MAIN board.
The buzzer sounds
intermittently after
the Main switch is
turned ON.
The CPU board is faulty. Replace the CPU board.
The START switch
does not work.
(RUN lamp not lit)
The other switches do not work, either.
The other switches work.
Replace the MAIN board.
Replace the panel switch
sheet.
The COOL switch
does not work.
(COOL lamp not lit)
The other switches do not work, either.
The other switches work.
Replace the MAIN board.
Replace the panel switch
sheet.
The MODE switch
does not work.
The other switches do not work, either.
The other switches work.
Replace the MAIN board.
Replace the panel switch
sheet.
Each shift key does
not work.
The other switches do not work, either.
The other switches work.
Replace the MAIN board.
Replace the panel switch
sheet.
The CHECK switch
does not work.
The other switches do not work, either.
The other switches work.
Replace the MAIN board.
Replace the panel switch
sheet.
The FUNCTION
switch does not
work.
The other switches do not work, either.
The other switches work.
Replace the MAIN board.
Replace the panel switch
sheet.
The RUN lamp
does not light.
The test operation is good.
Cannot start
Replace the PNL board.
Replace the MAIN board.
The COOL lamp
does not light.
Pressing the COOL switch starts the fan. Replace the PNL board.

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Table 2 Test Unit Troubleshooting
Problem Things to check Countermeasure
Samples are not
heated.
The heater has an open circuit.
The heater has no open circuit.
Replace the heater.
Replace the heater
SSR.
The heater output
does not become
OFF.
Go to the I/O check mode, Set SSR “off”
and then RL “on”, Heater output become
on.
The heater output is 100% after a start.
Replace the heater
SSR.
Replace the MAIN
board.
The cooling fan does
not operate.
24VDC is supplied to the fan.
24VDC is not supplied to the fan.
Replace the cooling
fan.
Replace the fan SSR.
The projection lamp
does not light.
A DC voltage (0-10V) is supplied to the
lamp.
No voltage is supplied to the lamp.
Replace the lamp.
Replace the MMB
board.
The receiving light
quantity is small.
(Occurs after starting
measurement)
Light is reaching the receivers.
Light is not reaching the receivers.
Replace the light
receiver assembly.
Adjust the lamp
position to project light
to the detectors.

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5. Parts Replacement
! Warning: When replacing parts, be sure to turn off the Mains
switch, unplug the power cable, and wait for one minute
or longer. Failure to do so may result in an electric shock
or fault.
! Caution: When making replacements, use genuine Tanaka parts
only.
5.1 Control Unit Parts Replacement
Be sure to note down the wiring arrangement before replacing parts so that the wiring
can be reconnected after replacement.
To remove the control unit cover, undo the four screws (two on either side) and lift the
cover up (see Fig. 16).
Fig. 21 Side of the Control Unit
(1) Replacing the CPU Board
The CPU board is inserted into a socket on the MAIN board. The socket prevents
reverse insertion.
When inserting the CPU board, check the connector labels, CNA (CN1) and CNB
Fixing Screws
(2 on each side)
Main Board
Control Unit
Co
v
er
Control Unit
Chassis

19
(CN2).
(When viewed from the panel, the internal battery is located on the right.)
(2) Replacing the ROM
Insert the ROM with its notch on the CN2 side, as shown in Fig. 22.
Fig. 22 The Arrangement of Parts in the Control Unit
(3) Replacing the fluorescent display
· Disconnect the cables connected to the panel on the main board from connectors
CN2 and CN3.
· Disconnect the power cable from CN1 on the fluorescent display board.
· Remove the four flat head screws from the sides of the panel and detach the panel
from the main unit.
· Remove the four screws securing the fluorescent display and disconnect the
connectors from the fluorescent display.
· Assemble the components in reverse order and check the cable connections.
Front
Main board
ROM CPU
Internal
batter
y
Connector code (CN1)
Connector code (CN2)
CNB (CN2)
CPU board
CNA (CN1)
ROM notch Internal battery
soldered on
the back of the
board
(2 places)
(−)
(＋)