Aco-8 Maintainace Ver1.02
Aco-8 Maintainace Ver1.02
Aco-8 Maintainace Ver1.02
Model aco-8
Maintenance Manual
IMPORTANT
*This Manual contains important technical
information as well as safety information.
*Read this Manual thoroughly before use, and
store in a safe place for future reference.
1
FOREWORD
Thank you for purchasing the aco-8 Automated Flash Point Tester, manufactured by
Tanaka Scientific Limited.
This manual contains all necessary information for the proper maintenance of the aco-8 unit
(possible readjustments, treatment of malfunctions, exchange of parts, etc.). Before
performing any maintenance on the aco-8, read this manual carefully and make sure that you
fully understand the instructions given herein.
In order to ensure safe operation of the aco-8 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.
● This manual addresses all users of the aco-8 Automated Flash Point Tester. It is presumed
that the user is familiar with related ASTM and JIS standards, and has experience in
working with potentially dangerous articles.
● Although this manual has been written and edited with the most 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.
2
BEFORE STARTING M AINTENANCE WORK
● Before performing any maintenance work on the aco-8, 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.
● 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.
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 aco-8 with bare hands when operating the
device. These parts produce extreme heat and may cause serious burns.
! 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
aco-8 and immediately contact the manufacturer or an authorized distributor.
3
! 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.
4
Contents
FOREWORD ............................................................................................................................ 2
1.1. Cleaning of Test Cup, Detector Assembly and Fire Containment Lid .................. 7
2.1.5 Louver............................................................................................................. 21
2.2.5 Thermofuse..................................................................................................... 26
5
2.2.8 Igniter top....................................................................................................... 31
6
1 PERIODIC INSPECTIONS
In order to maintain accurate performance of the aco-8 and to guarantee safe operation of the device,
periodic inspections must be performed at regular intervals
LID
(1) Clean Test Cup using some solvents if there is some deposit in the cup. Heat Test Cup and
scrape the deposit away by wooden spatula if the deposit cannot be removed by solvent.
(2) Clean the detector assembly (around detector rings) using some solvents once in a week.
Refer FIG. 2 for this procedure. If some sample sticks to the detector assembly, malfunction
may be occurred. Dry the detector assembly well before the next test.
(3) Clean the fire containment lid and pivot shaft (FIG.3) using some solvents once in a week.
7
FIG. 2 Cleaning of Temperature Sensor (left) and Detector Ring (right)
8
1.2 TEMPERATURE CALIBRATION
1.2.1 PREPARATION
(a) Prepare ASTM 11C mercury-in-glass thermometer. (Use ASTM 11F when the temperature
unit setting is oF, and convert following temperature value to degree F.)
(b) Set a standard glass thermometer fixing the arm so that the tip of thermometer positioned
6.0 – 7.0 mm away from the bottom of Test Cup.(FIG. 6) A “Mercury Thermometer Holder
for Calibration” (option) is useful to fit the thermometer.(FIG. 7)
9
(c) Turn off the cock of gas line.
EXP FP 100
Sample ID AAAAAAAAAAAA
Method I SO / J I S F ire
OK
23.4 o
10
1.2.2 DISPLAYING TEMPERATURE CORRECTION
(1) Correction by Each Point
This tester has temperature correction point every 40oC between 0 oC to 400 oC.
The relationship between actual value of the temperature sensor and the displaying temperature
is shown in FIG. 10
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 oC) are determined by
linear interpolation.
80oC
Temp Correction
79oC
B a c k
Display Temperature
41oC
POS +0.0 0 +0.0 40 +1.0 40oC
80
保 -1.0
保 120
保 +0.0
保 160
保 +0.0
保
200
存 +0.0
存 240
存 +0.0
存 80
存280 +0.0
存
デ
320 デ
+0.0 デ
360 デ
+0.0 デ
400 デ
+0.0 0oC
ー ー ー ー ー ー 0oC 40oC 80oC
タ タ タ タ タ タ
Actual Value of the Temperature
Sensor
11
(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. 11
Display Temperature = Actual Value of the temperature sensor + Offset Value of each
correction point + POS Offset Value
Display Temperature
Temp Correction 80
B a c k
42
POS +1.0 0 +0.0 40 +1.0 41
80
保 -1.0
保 120
保 +0.0
保 160
保 +0.0
保 42
200
存 +0.0
存 240
存 +0.0
存 80
存280 +0.0
存
デ
320 デ
+0.0 デ
360 デ
+0.0 デ
400 デ
+0.0
ー ー ー ー ー ー 1
タ タ タ タ タ タ 0
0 40 80
Actual Value of the Temperature
12
2. GAS LEAK INSPECTION
(Once per 3-month for outside and once per year for inside the tester)
! 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.
Follow the instructions below to check the gas lines of the aco-8 unit for possible leaks.
(2) Detach right side cover and top cover of the test unit. (refer to 2.1.1 & 2.1.2)
(3) Reinsert the power plug to the wall socket and turn ON the main switch.
13
FIG. 15 Adjusting Screen Indication
(4) 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.16)
Config Screen
Back
Initialize
Model&S/N&Std Set
I/O Check
Sample 0-span
Bath 0-span
14
(5) Press the Up-Down key and choose I/O Check and press OK key.
(7) Press the Up-Down key to move the cursor to Gas Valve.
(10) Press the Up-Down key and change it from Off to On by that the solenoid valve is opened.
(13) Press OK key again and it will open the solenoid valve and start gas flow.
(14) Please inspect pluming connection by gas leak with soap water or gas leak detection spray.(FIG.
20,FIG. 21 and FIG. 22)
When you find Gas leak, please stop using aco-8 and inform Tanaka scientific limited or distributor
immediately.
15
FIG. 18 Gas Leak Detection Splay
16
FIG. 21 Gas Leak Inspection (2)
(15) After completion of the inspection, press the RESET key. This will shut the solenoid valve.
(16) Turn OFF the main switch and remove the power plug from the wall socket.
(17) Attach right side covers and then top cover onto the test unit.
17
2 PARTS REPLACEMENT
Warning: For component replacement, turn the main switch OFF, disconnect the power plug,
and wait for one minute. Failure to follow this procedure may result in electric shock or
damage the instrument.
(3) Pull the side cover upward while opening the cover upper end outward. ( )
18
2.1.2 TOP COVERS
(1) Loosen Top Cover fixing screw. ( )
19
2.1.4 ARM COVER
(1) Loosen Arm cover fixing screws. (both sides) ( FIG 26)
(2) Pull the arm cover while lifting the rear side by approx. 1 cm. ( FIG 27 )
20
2.1.5 LOUVER
(1) Detach both side covers (refer to chapter 2.1.1)
(2) Detach the middle cover fixing screws ( 4 places shown in FIG. 29)
21
2.2 PARTS REPLACEMENT
(2) The CPU board is installed on the MAIN board. Detach CPU Board from main board, and then
install new CPU board so that gibbous part of the plug matches to the chipped socket ( ) of
the main board.
(2) Detach all the connectors on the main board, and then unscrew six screws ( FIG 31).
Please check that white arrow on the MAIN Board is showing your side and forward of the
instrument.
22
2.2.3 USB BOARD
(1) Remove left side cover (refer to chapter 2.1.1).
(2) Detach all connectors on the USB board and then, unscrew four screws ( FIG. 32)
(2) Unscrew fixing screws for the operation /display panel ( FIG. 33 and FIG. 34)
(4) After detach all flat cables and connectors ( and FIG. 36) on the panel board,
unscrew four screws ( FIG. 36).
(5) In reverse procedure, attach screws, connectors and flat cable, and then attach control unit
back to place before detached.
23
FIG. 33 Fixing Screws for Operation / Display Panel (1)
24
FIG. 35 Split Up the Operation / Display Panel and Main Body
25
2.2.5 THERMOFUSE
(1) Detach arm cover (refer to chapter 2.1.4).
(2) Loosen screws on the thermo fuse terminal block ( shown in FIG. 37), and then pull out
thermo fuse together with the insulation tube.
(3) Cover new thermo fuse with insulation tube (FIG. 38), and then attach thermo fuse on the
terminal block.
26
2.2.6 TEMPERATURE SENSOR FOR SAMPLE
(1) Detach Arm cover (refer to chapter 2.1.4)
(2) Loosen Temperature sensor ( shown in FIG. 39) Fixing screw ( Shown in FIG. 39),
and then pull towards .
Make sure the position of the sensor is approx. 1 mm from the bottom of test cup (FIG. 41)
27
FIG. 40 Temperature Sensor Terminal
* is Temperature Sensor Electrical Ground
28
2.2.7 DETECTOR RINGS (CLEANING)
(1) Loosen inside and outside detectors ( Shown in FIG. 42) Fixing screws ( shown in
FIG. 42 ), and then pull downwards
Make sure the position of the ring is approx. 3-4 mm from the top of test cup (FIG. 43)
< Cleaning>
Usually, wipe by acetone, however if it’s not cleaned off completely by solvent, detach the rings and
scrub with fine sand paper softly.
Warning: Please scrub detector Rings nice and softly, otherwise the welding part get damage.
29
FIG. 43 Detector Rings Mounting Position
30
2.2.8 IGNITER TOP
(1) Pull Igniter Top ( shown in FIG. 44) towards (FIG. 44)
Warning: When you replace igniter top, please do not pull up and down, left and right, otherwise
igniter base might get damage ( shown in FIG. 44)
31
2.2.9 HEATER
Warning: aco-8 may be broken if the heater coil touches heater case. When replacing heater, confirm
it before the MAIN switch ON.
(1) Detach Heating plate (upper) ( shown in FIG. 45), and then detach heating plate (lower)
( shown in FIG. 45) fixing screw (2 places)
(2) Detach heater unit fixing screw ( 3 places shown in FIG. 46) and heater lead wires ( 2
places shown in FIG. 47), and then pull heater unit upward.
(3) Detach heater unit terminal block nuts ( 2 places shown in FIG. 48), and pull heater case
upward.
(5) Confirm heater coil does not touch heater case then, in reverse procedure attach it again.
32
FIG. 46 Heater Unit
33
FIG. 48 Heat Unit
34
2.2.10 GAS SOLENOID VALVE
(1) Detach Right side cover (refer to chapter 2.1.1).
(2) Detach solenoid valve stay fixing screw ( 2 places shown in FIG. 50).
(3) Detach solenoid valve fixing screws ( 2 places shown in FIG. 51).
(4) Replace hose nipple and L-joint, and then attach new Gas Solenoid Valve in reverse procedure.
(Make sure to cover Nipple and L-joint with Seal Tape when replacing.)
35
2.2.11 COLOR LCD
(1) Detach Operation / Display panel (refer to 2.2.5)
(2) Detach Flat cable on the panel board ( shown in FIG. 52) and also, detach color LCD fixing
screws ( 4 places shown in FIG. 52).
FIG. 53 From the Left, Display Cover, LCD, Acrylic Plate and Display Panel
36
2.2.12 SWITCHING POWER SUPPLY
<5V part>
(1) Detach Left side cover (refer to chapter 2.1.1), and Rear cover (refer to chapter 2.1.3) and then
main board.
(2) Detach lead wires from switching power supply and also detach power supply stay fixing screws
( 2 places shown in FIG. 54).
(3) Detach switching power supply fixing screw ( 2 places shown in FIG. 55).
37
<24V part>
(1) Detach left side cover (refer to chapter 2.1.1) and back cover (refer to chapter 2.1.3).
(2) Detach lead wires from switching power supply terminal., and also detach power supply stay
fixing screws ( 2 places shown in FIG. 56)
(3) Detach switching power supply fixing screws ( 2 places shown in FIG. 57)
38
2.2.13 PHOTO MICRO SENSOR (FOR ARM)
(1) Detach top cover (refer to chapter 2.1.2) and middle cover (refer to chapter 2.1.6) and pull
connector ( FIG 59)
(2) Detach sensor stay fixing screw ( 2 places shown in FIG 60)
FIG. 58 Mounting Position of Photo Micro Sensor for Arm (Red Arrow)
39
FIG. 59 Arm Sensor Stay Fixing Screws
40
2.2.14 PHOTO MICRO SENSOR (FOR TEST FLAME NOZZLE)
(1) Detach arm cover (refer to chapter 2.1.4)
(2) Detach arm chassis ( shown in FIG. 61) fixing screw (4 places shown in FIG. 61)
(3) Detach Sensor fixing screw ( 2 places each shown in FIG. 62)
41
2.2.15 PANEL SWITCH SHEET
(1) Detach operation / display panel and then flat cable from panel board (refer to chapter 2.2.5).
42
2.2.16 INSULATION COLLAR (CLEANING)
(1) Detach two (2) nuts ( shown in FIG. 64) above top part of Insulation collar ( shown in
FIG. 64)
(2) Pull outter detector ring ( shown in FIG. 64) and pull electrode bar ( shown in FIG.65)
downwards, and then detach lower insulation collar ( shown in FIG. 64)
(3) Clean insulation collar and inside part of detector ring guide ( shown in FIG. 64) by solvent
such as acetone, and then dry it.
(5) After that, Turn the power ON, and then push Emergency Switch to activate Fire Containment Lid
to confirm the Fire containment Lid does not touch the detector ring fixing screw. If the Lid
touches to the screw, the lid may not cover the test cup.
Remarks: If insulation does not recover after cleaning, replace both upper and lower insulation
collars to new one.
43
From above,
M3 hexagon nut
Spring Washer
Plain Washer
Terminal
Plain Washer
hexagon nut
Spring Washer
Plain Washer
Insulation Collar
44
Appended Table 1 aco-8 Setting Table
S/N:
Name:
Date:
Spare
Parameter, etc.
First Appl. Detector
Initial Heat Cooling Time
Temp. Sens.
( ) ( ) ( ) ( )
Pre Flash
Check RS-232C
Filament
Output Baud Rate/Data Bits/Parity/Stop Bits/Line
ON(> )/ Feed
OFF
Interval( ( )( )
( )
) ( )( )( )
Password Hint:
45