JFTOT II JET FUEL THERMAL OXIDATION TESTER

Service Manual / October 2003

Version 2.1or later

300 BAMMEL WESTFIELD ROAD • HOUSTON, TEXAS 77090 USA

TELEPHONE: 281-580-0339 • FAX: 281-580-0719
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TABLE OF CONTENTS

1. SYSTEM DESCRIPTIONS ...................................................................................................................... 1

1.1 Fuel System .................................................................................................................................... 1
1.2 Cooling System ............................................................................................................................... 1
1.3 Fuel Aeration System ..................................................................................................................... 1
1.4 Electrical System ............................................................................................................................ 2
2. MENUS AND DISPLAYS .................................................................................................................... 17
2.1 Menus ...........................................................................................................................................17
2.2 Error Messages .............................................................................................................................20
3. FUEL SYSTEM ........................................................................................................................... 25
3.1 Checking fuel Reservoir and Piston ..............................................................................................25
3.2 Replacing the drive belt .................................................................................................................25
3.3 Replacing drive Pump ...................................................................................................................25
3.4 Servicing The Drive Pump ............................................................................................................25
3.5 Installing new Lines ......................................................................................................................26
3.6 Components of Fuel System .........................................................................................................26
4. COOLANT SYSTEM .................................................................................................................. 35
4.1 Coolant ..........................................................................................................................................35
4.2 Installing New Lines .....................................................................................................................35
4.3 Coolant pump ................................................................................................................................35
4.4 Bus Bar Jets ..................................................................................................................................35
4.5 Installation Details .........................................................................................................................35
5. AERATION SYSTEM ................................................................................................................ 41
5.1 Air Pump .......................................................................................................................................41
5.2 Installing New Lines .....................................................................................................................41
5.3 Routing Air lines ............................................................................................................................41
6. ELECTRICAL SYSTEM ............................................................................................................ 43
6.1 Computer And Interface Boards ...................................................................................................43
6.2 Maintenance Menu .......................................................................................................................43
6.3 Relay Modules ..............................................................................................................................44
6.4 Voltage checks for pressure transducers ......................................................................................44
6.5 Checking drive pump flow rate .....................................................................................................45
6.6 Checking And Adjusting The Drive Pump Speed Control Sensor (Tach Sensor). ........................46
6.7 Motor speed Control .....................................................................................................................46
6.8 Interface Board for JFTOT-II S/N 200 to 245. ............................................................................46
6.9 Replacing pressure transducers ....................................................................................................47
6.10 Checking and Adjusting the SCR Power Control ..........................................................................47
6.11 Printer specifications .....................................................................................................................48
6.12 Components of the electrical system .............................................................................................48
6.13Electrical Schematics .....................................................................................................................48
7. TECHNICAL INFORMATION BULLETINS (TIBS) ............................................................. 67

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1. SYSTEM DESCRIPTIONS

There are four basic systems in the JFTOT II: tube and its outer stainless steel housing. A
low-voltage, high current AC signal is passed
Fuel System
through the heater tube to produce resistance
Cooling System
heating. Exiting the heater tube section, the fuel
Fuel Aeration System
passes through a test filter having an element
Electrical System
made from stainless steel cloth with a rated
Figures 6.14 through 6.17 are attached to aid the porosity of 17 microns.
descriptions of the four basic systems.
1.1.5 The test filter can be bypassed at any time,
normally when the ∆P reaches 250 mm Hg.
1.1 FUEL SYSTEM The fuel reaches a water reservoir by either
1.1.1 The syringe drive pump uses the hydraulic route and displaces the water contained
action of the reservoir piston to produce therein. The water proceeds through a pres-
pressure on the fuel system. A regulator at the sure regulator then drips from a line into an
outlet of the system maintains the pressure at a open container. The drip line allows visual
constant value by maintaining a constant monitoring of the flow rate.
“leak”. The control is precise because the
regulator sees only water which is displaced by 1.2 COOLING SYSTEM
the test fuel. An absolute pressure transducer
A self contained, closed loop cooling system provides
measures the fuel pressure on the overall
for bus connector cooling. The JFTOT has a flow
system. The transducer sends a signal to the
adjustment valve and rotameter type flow indicator to
controller to ensure the pressure is maintained
set the rate at 10 gal/hr (38 ± 8 L/h). A coolant
above 450 psig.
reservoir provides coolant to a water pump. The
1.1.2 Before pressurizing, the fuel system is bled of water is pumped through a fan cooled radiator to cool
any air so there will be no bubbles in any part the water before entering the bus bars. The water
of the system that could be under high pressure lines are electrically insulated from the bus connec-
during a test. The air trap assembly is used tors by means of polyethylene tubing. The water
during the air bleeding process to confirm the flows through the flow control valve and the rotame-
system has been bled properly. ter before returning to the coolant reservoir.
1.1.3 The test fuel is forced from the fuel reser-
1.3 FUEL AERATION SYSTEM
voir through the test section by action of the
rising piston. The pump is driven by a speed- 1.3.1 A system provides dry, filtered air at 1.5 L/min
controlled motor to produce a displacement of for six (6) minutes. The 9.0 liters thus passed
3 ml/min. through the fuel ensures at least 97% of air
saturation. An air pump, flow adjustment valve,
1.1.4 From the reservoir outlet, the fuel flows
and rotameter type flow indicator provides the
through a 0.45 micron membrane type filter,
air flow. The computer automatically turns the
thence to the lower (inlet) part of the heater
air pump off after six (6) min.
test section. The heater tube is connected
between two electrically powered busses and 1.3.2 A silica gel filled container is used to dry and
is electrically insulated from the outer housing filter the air before entering the fuel.
by means of a non-conductive ferrule/o-ring
combination. The fuel rises vertically in the 1.3.3 A sintered glass tube is used to bubble the air
annular space between the aluminum heater through the fuel in a sparging action.

JFTOT II Service Manual Rev. C Page 1

1.4 ELECTRICAL SYSTEM b. the time when the pressure reaches 2,
10, 15, 25, 50, 75, and 125 mm Hg
1.4.1 Heating and Temperature Control System respectively.
• The heater tube is heated by conduction of c. the time to 25 mmHg, the maximum ∆P,
an electrical current of approximately 200 to and the time to open bypass for view on
300A at 0.3 to 0.5 VAC. The heater tube is the display at the end of the test.
clamped at each end into busses having
corrosion resistant contact surfaces. The • The differential pressure system is cali-
busses are cooled by internal water lines; brated to include a 6% bias. This bias is
they receive electrical power from a low added to make DPT readings equivalent to
voltage transformer that is matched to the the early JFTOTs that used a mercury
electrical resistance of the heater tube. manometer. This bias is predictable, based
on the density of mercury and the test fuel.
• The controller provides both temperature A factory calibrated DPT checked against
indication (MAN mode) and automatic an absolute standard, such as a dead weight
control (AUTO mode). The input signal to tester or air/mercury manometer should
the controller is from a thermocouple read about 6% higher than true (e.g. DPT
inserted through the top of the heater tube reading of 265 mmHg with a 250 mmHg
and positioned at the point of maximum differential pressure applied).
temperature. This thermocouple can be
positioned at any point along the heated 1.4.3 Thermocouple Calibration System
portion of the tube for the purpose of The AutoCal calibration system provides for a
obtaining a temperature profile. The sliding reliable check of the calibration of the entire
scale assembly is provided to define the temperature indication system by utilizing the
position of the thermocouple junction with freezing point of Water (0°C), 99% pure Tin
0.0 station being the heater tube’s lower (232°C) and pure Lead (327.5°C) as the
shoulder. standards. The AutoCals consist of a special
1.4.2 Differential Pressure Measurement System heater tube device which has at its middle
section a small well containing the pure Tin or
• A Differential Pressure Transducer (DPT) Lead into which the thermocouple is immersed.
is used to measure the differential pressure The test thermocouple is introduced into the
across the test filter as the filter fouls with Tin or Lead after raising the temperature
products from the fuel degradation. The above the melting point. The cool-down
transducer is connected across the test filter temperature-time characteristic is observed by
as per Figures 5.2 and 5.3. The DPT is the computer, which determines the tempera-
controlled by two valves: FLOW CON- ture indication at which the temperature
TROL SELECTOR VALVE and an pauses. Any difference between this reading
electric bypass valve located inside the and the true freezing temperature is the error in
JFTOT. The first valve provides a means to the temperature measurement system. This
vent and eliminate any air from the system error is recorded by the computer and applied
when required. The second valve allows the as a correction when displaying subsequent
test fluid to bypass the filter. The bypass heater tube temperatures.
valve is operated automatically by the
computer when the pressure across the 1.4.4 Test Time Measurement
filter exceeds 250 mm Hg. This allows the The computer provides all time measurements.
test to continue to obtain heater tube The computer contains a crystal oscillator to
deposits for the full test period. maintain accurate time. The time remaining in
• The computer records the following: the test is displayed in minutes and seconds.
a. the differential pressure every 30 min.

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 FIGURE 1.1 - FRONT VIEW OF THE JFTOT II

JFTOT II Service Manual Rev. C Page 3

 FIGURE 1.2 - REAR VIEW OF THE JFTOT II

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 FIGURE 1.3 - VIEW OF THE JFTOT II ELECTRONICS PANEL

JFTOT II Service Manual Rev. C Page 5

1. Aeration Flow Meter (58030) 14. Water Reservoir Vent Line (43931)
2. Aeration Air Outlet 15. Water Reservoir Inlet Line (43930)
3. Cooling Flow Meter (58029) 16. Additional Fitting (Model 240 Only)
4. Thermocouple Reference Line 17. Heater Section Outlet Line (43765)
5. Thermocouple Position Indicator 18. Filter Bypass Line (part of 35291)
6. Thermocouple Position Control 19. Lower Floating Bus (part of 10830)
7. Thermocouple (86300) 20. Reservoir Outlet Line (43923)
8. Computer Display (24634) and 21. Heater Tube Test Section (35291)
Keypad (80882) 22. Test Filter Housing (part of 35291)
9. Glass Jar For Air Bleed (17621) 23. Upper Fixed Bus ([part of 10830)
10. Drip Flow (Water) 24. Thermocouple Plug In
11. Water Beaker (17643) 25. Fuel Resrvoir (63332)
12. Water Reservoir (63320) 26. Prefilter (27042)
13. Water Outlet Fitting (28351)

FIGURE 1.4 - TEST COMPONENTS, MODEL 230

TEST COMPONENTS, MODEL 240 (ADD TIME REACTOR)

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 FIGURE 1.5 - MODEL 230 SYSTEM FLOW CHART

JFTOT II Service Manual Rev. C Page 7

 FIGURE 1.6 - MODEL 240 SYSTEM FLOW CHART

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 FIGURE 1.7 - ASSEMBLY DRAWING OF HEATER TUBE TEST SECTION

JFTOT II Service Manual Rev. C Page 9

 FIGURE 1.8 - HEATER SECTION WITH NO TIME REACTOR,
(1 ∆P, MODEL 230 OR 240)

FIGURE 1.9 - HEATER SECTION AND TIME REACTOR,

WITHOUT INSULATION (2 ∆P, 240 ONLY)

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 FIGURE 1.10 - TIME DELAY REACTOR, MODEL 240 ONLY (35375) PLUS LINE (43925)

JFTOT II Service Manual Rev. C Page 11

 FIGURE 1.11 - SYRINGE PUMP AND FUEL RESERVOIR

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 FIGURE 1.12 - WATER RESERVOIR (63320)

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 FIGURE 1.13 - COOLING SYSTEM

FIGURE 1.14 - AERATION SYSTEM

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 FIGURE 1.15 - HEATER TUBE POWER AND
TEMPERATURE CONTROL SCHEMATIC

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2. MENUS AND DISPLAYS

Two very powerful features of the JFTOT-II are the 4. Test Setup Screen #1
REFRESH and PRINT SCREEN buttons on the (CUSTOM TEST with 1dP cells being used)
keypad. Whenever you are looking at a menu and (not calibrated)
see something that looks inappropriate, press the
REFRESH key so the computer will re-write the
display. If the menu still appears incorrect, press the
PRINT SCREEN key so the computer will print the
complete display to the printer. This print out can be
faxed to customer service to help troubleshoot and
resolve problems.
The following Menus are displayed as a result of user
selection by the keypad. 5. Test Setup Screen #1
2.1 MENUS (D3241 TEST…only 1dP cell can be used)
(must be calibrated)
1. Main Menu Screen

6. Test Setup Screen #2

2. Test Setup Screen #1
(CUSTOM TESTS only)
(CUSTOM TEST with 2dP cells being used)
(not calibrated)

7. Test running screen on entry:

3. Test Setup Screen #1 (test not started yet)
(CUSTOM TEST with 2dP cells being used)
(calibrated)

JFTOT II Service Manual Rev. C Page 17

8. Test running screen: 11. Test running screen:
(test is running) (test is running)
(tube profiling not allowed yet) (tube profiling allowed)
(system has “tared” the dP values) (system has “tared” the dP values)
(heater in automatic mode) (heater in manual mode)

F3: F4:

9. Test running screen: 12. View history screen:

(test is running) (no tests in memory)
(tube profiling allowed)
(system has “tared” the dP values)
(heater in automatic mode)

13. View history screen:

(1 test in memory)
(the test was saved but the test never “tared”
the dp values)
10. Test running screen:
(test is running)
(tube profiling allowed)
(system has “tared” the dP values)
(heater in automatic mode)
(system pressure is currently drifting)
(each differential pressure cell crossed
25mmHg)
14. View history screen:
(more than 1 test in memory)

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15. View history screen: 19. Maintenance screen on entry.
(more than 1 test in memory) (the remote computer is connected and ready
(this test was a “D3241” test) for data)

16. Maintenance screen on entry. 20. Autocal screen - initial screen.

(NOT CALIBRATED)
(just after power up)

17. Maintenance screen

(drive pump on…going down)
21. Autocal screen - initial screen.
(NOT CALIBRATED)
(after 20 minute power up time)

18. Maintenance screen

(drive pump on…going up)
22. Autocal screen - initial screen.
(THERMOCOUPLE SYSTEM CALIBRATED)
(after 20 minute power up time)

JFTOT II Service Manual Rev. C Page 19

23. Clock menu screen 28. System setup screen.
(timed real-time transmit of test information)

24. Change date & time screen

(mm/dd/yy format) 29. System setup screen
(transmit real-time test information only when
asked by remote system)

25. Change date & time screen

(dd/mm/yy format)
30. System setup screen
(use the network machine identifier sequence)
(19200 baud rate)

26. System setup screen

2.2 ERROR MESSAGES

The following information and error messages are
displayed by the JFTOT to alert the user to the status
of the JFTOT (i.e. if ready, test finished, errors, etc.),
and may also tell how to proceed.
27. System setup screen Error messages outputted from trying to view
(only 1 dp in system) historical test records:

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Error messages outputted from the Autocal Error messages ouputted from system initialization:
operation:

16

JFTOT II Service Manual Rev. C Page 21

Error messages for system faults that are checked
almost all times throughout the entire program.

Error messages outputted while trying to print a

report:

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Error messages outputted while trying to run a test:

OR

OR

OR

OR

OR

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3. FUEL SYSTEM

3.1 CHECKING FUEL RESERVOIR AND 3.4 SERVICING THE DRIVE PUMP
PISTON
The drive pump may require service due to several
The fuel reservoir and piston (with lip seal) should be reasons:
inspected after every test. There can not be any
scratches or nicks on their mating surfaces. Check 1. The lip seal has leaked fuel into the drive pump
the reservoir (must be dry) by looking through it at a and washed out the grease.
light. Any scratches that look like you could snag 2. The drive belt is slipping making a “popping”
your finger nail on it is too big. As needed, either sound. First check to make sure no fuel lines are
replace the reservoir (and piston) or have the reser- plugged and the prefilter contains a WHITE filter
voir honed. The maximum inside diameter of the element (the blue wax paper separator will plug
reservoir is 2.278". the filter).

3.2 REPLACING THE DRIVE BELT Before removing the pump, remove the drive belt.
You should be able to easily turn the large pulley by
Follow these steps to remove the drive pump belt. hand. If not, grease the pump using the two grease
Reverse order to install the drive pump belt. nipples provided. If the large pulley still does not turn
easily by hand then the pump needs to be removed,
1. Remove the fuel reservoir from the top of the
dissassembled and inspected.
drive pump.
1. Remove the drive belt.
2. Loosen the four motor mounting bolts. Slide the
motor towards the drive pump column. (When 2. Remove the large pulley: remove the two bolts
installing, see TIB 008 for proper belt tension from the large pulley, then re-install the bolts into
adjustment.) the thread holes in the pulley hub. Tightening
these bolts will now remove the hub from within
3. Push belt down over edge of small pulley first,
the pulley, allowing you to remove the pulley
then the large pulley.
from drive screw shaft.

3.3 REPLACING DRIVE PUMP CAUTION - the screw shaft will now be loose in
the pump column.
Follow these steps to remove the drive pump.
Reverse order to install the drive pump. 3. Remove and inspect the thrust bearing and two
washers.
1. Remove the fuel reservoir from the top of the
drive pump. 4. Remove the roller cam bearing from the drive
nut.
2. Remove the six screws and ring from top of test
panel. 5. Remove the screw shaft with drive nut and main
taper bearing. The nut and bearing may be
3. Unplug the 15-pin connector. inspected and lubricated while still on the shaft.
4. Remove the four bolts from the bottom of the 6. Look for excessive wear on the main taper
JFTOT that secure the drive pump. bearing and on the screw shaft. If present, the
shaft and bearing may need to be replaced.
5. Slide bottom of drive pump out through back of
JFTOT.

JFTOT II Service Manual Rev. C Page 25

7. If, and only if, the shaft is badly worn, inspect the 1. Insert tubing into the Swagelok fitting. Make sure
needle bearing in the flange housing. Remove the that the tubing rests firmly in the shoulder of the
six bolts to separate the column and flange fitting and the nut is finger-tight.
housing from the mounting plate. Do not attempt
to remove or replace the needle bearings. Special 2. Before tightening the Swagelok nut, scribe the
tooling is required to install the needle bearing nut at the 6 o’clock position (or use a pen or
and the alignment ring into the flange housing. If pencil).
the needle bearings are damaged, it is best to 3. Hold the fitting body staedy with a backup
reassemble the drive and return to PAC/Alcor wrench and tighten the nut 3/4 turns. Watch the
Petroleum Instruments for repair. scribe mark, make one complete revolution and
8. Re-assemble in reverse order. Grease all bear- continue to the 9 o’clock position. By scribing the
ings and mating surfaces during assembly. Use a nut, there will be no doubt as to the starting
multi-purpose grease containing Molybdenum position of the nut, and you can easily see that
Disulfide (moly grease). To assemble the large the fitting has been properly tightened.
pulley move the two bolts to the non-threaded NOTE: 3/16" diameter and smaller tubing re-
holes in the hub and screw into the pulley. Push quires tightening the nut only 3/4 turns, but 1/4"
the large pulley onto the shaft so there is and larger tubing requires tightening the nut 1-1/
0-0,2 mm (0-.007") endplay. (You can hold the 4 turns.
shaft in place by adjusting the nut so the cam
follower bearing is at the top of the slot in the When retightening already swaged fittings tighten to
column, pushing in the shaft.) Don’t forget to snug, DO NOT turn the nut 3/4 to 1-1/4 turns.
install the key when installing the large pulley.
3.6 COMPONENTS OF FUEL SYSTEM
3.5 INSTALLING NEW LINES Detailed views are provided to show the various
When installing new fuel lines, make sure you use components of the fuel system.
new Swagelok ferrules and swage them properly.
Swagelok fittings are installed in three easy steps:

Page 26 JFTOT II Service Manual Rev. C

 FIGURE 3.1 - LINE PART NUMBERS, MODEL 230

JFTOT II Service Manual Rev. C Page 27

 FIGURE 3.2 - SCREW DRIVE ASSEMBLY INSTALLATION

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 FIGURE 3.3 - COLLAR ASSEMBLY

FIGURE 3.4 - 5-WAY VALVE ASSEMBLY

JFTOT II Service Manual Rev. C Page 29

 FIGURE 3.5 - DRIVE PUMP ASSEMBLY (60117)

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 FIGURE 3.6 - PRESSURE REGULATOR ASSEMBLY

FIGURE 3.7 - FUEL VAPOR TRAP ASSEMBLY

JFTOT II Service Manual Rev. C Page 31

 FIGURE 3.8 - DIFFERENTIAL PRESSURE TRANSDUCER ASSEMBLY

FIGURE 3.9 - BULKHEAD FITTING ASSEMBLY (TYP., 4 PLCS)

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 FIGURE 3.10 - QUICK CONNECT ASSEMBLY FOR WATER RESERVOIR

FIGURE 3.3.11 - BULKHEAD UNION FITTING

(discard 1 each nut, front and rear ferrules)

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Page 34 JFTOT II Service Manual Rev. C

4. COOLANT SYSTEM

4.1 COOLANT provide this 16VDC. When installing a new coolant

pump, first completely drain and flush the system
The coolant system pumps a 50/50 mixture of water with water, then refill with new coolant.
and ethylene glycol (anti-freeze) throught the bus
bars to keep them cool during operation. The coolant
reservoir should be about half full while the coolant
4.4 BUS BAR JETS
pump is in operation. The bus bars are hollow to allow water cooling. The
bus bars jets deliver water to the end of the bus bars
4.2 INSTALLING NEW LINES and allow the cooling water to return along the inside
surface of the bus bar. When installing new jets
The coolant system uses two types of tubing for insert the tube to the end of the bus bar, then retract
lines. The pump lines are 5/16" dia flexible Tygon® 6mm (1/4"). Secure with new Swagelok 1/4" nut and
tubing (49292) and the remainder are 1/4" dia. ferrules. Swagelok fittings are installed in three easy
polyethylene tubing (49291). steps:
• Cut the flexible vinyl tubing to length, and install the 1. Insert tubing into the Swagelok fitting. Make
old brass inserts into the end of the new tubing. sure that the tubing rests firmly in the shoulder
Then install into fitting using new Swagelok 5/16" of the fitting and the nut is fingertight.
nuts and ferrules.
• Cut the 1/4" dia. polyethylene tubing to length. 2. Before tightening the Swagelok nut, scribe the
nut at the 6 o’clock position (or use a pen or
Then install into fitting using new Swagelok 1/4"
pencil).
nuts and ferrules.
• Swagelok fittings are installed in three easy steps: 3. Hold the fitting body steady with a backup
1. Insert tubing into the Swagelok fitting. Make wrench and tighten the nut 1-1/4 turns. Watch
sure that the tubing rests firmly in the shoulder the scribe mark, make one complete revolution
of the fitting and the nut is finger-tight. and continue to the 9 o’clock position. By
scribing the nut, there will be no doubt as to the
2. Before tightening the Swagelok nut, scribe the starting position of the nut, and you can easily
nut at the 6 o’clock position (or use a pen or see that the fitting has been properly tightened.
pencil).
3. Hold the fitting body steady with a backup 4.5 INSTALLATION DETAILS
wrench and tighten the nut 1-1/4 turns. Watch Detailed views are provided to show how to install
the scribe mark, make one complete revolution the lines, coolant radiator, fan, water pump, and bus
and continue to the 9 o’clock position. By jets.
scribing the nut, there will be no doubt as to the
starting position of the nut, and you can easily
see that the fitting has been properly tightened.

4.3 COOLANT PUMP

The coolant water pump contains a 24VDC motor
and provides a flow rate in excess of 40 L/hr. (10
gal/hr.). The proper voltage input and water inlet and
outlet fitttings are shown below. To provide extened
service, the pump motor is operated at a reduced
voltage of 16VDC. A stepdown resistor is adjusted to

JFTOT II Service Manual Rev. C Page 35

 FIGURE 4.1 - COOLANT SYSTEM

FIGURE 4.2 - DETAIL “M” RADIATOR/FAN ASSEMBLY

Page 36 JFTOT II Service Manual Rev. C

 FIGURE 4.3 - DETAIL “L” PUMP ASSEMBLY

JFTOT II Service Manual Rev. C Page 37

 FIGURE 4.3 - DETAIL “N”

FIGURE 4.4 - DETAIL “P” AERATOR ASSEMBLY

Page 38 JFTOT II Service Manual Rev. C

 FIGURE 4.5 - BUS BAR ASSEMBLY

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5. AERATION SYSTEM

5.1 AIR PUMP 2. Before tightening the Swagelok nut, scribe the
nut at the 6 o’clock position (or use a pen or
The air pump operates on 24VDC and provides a pencil).
flow rate in excess of 1.5 L/min. A diagram of the
aeration system is provide in Figure 1.14. 3. Hold the fitting body steady with a backup
wrench and tighten the nut 1-1/4 turns. Watch
5.2 INSTALLING NEW LINES the scribe mark, make one complete revolution
and continue to the 9 o’clock position. By
Cut the 5/16" dia. Tygon™ tubing to length, and scribing the nut, there will be no doubt as to the
install the old brass inserts into the end of the new starting position of the nut, and you can easily see
tubing. Secure with new Swagelok 5/16" nut and that the fitting has been properly tightened.
ferrules. Swagelok fittings are installed in three easy
steps:
5.3 ROUTING AIR LINES
1. Insert tubing into the Swagelok fitting. Make sure A detail view for routing the air lines is provided with
that the tubing rests firmly in the shoulder of the the views for the coolant lines (see Section 4.0).
fitting and the nut is fingertight.

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Page 42 JFTOT II Service Manual Rev. C

6. ELECTRICAL SYSTEM

6.1 COMPUTER AND INTERFACE normally displayed during a JFTOT test (i.e. tem-
BOARDS perature and pressure). These four values corre-
spond to a channel number:
The JFTOT is controlled by a 8-bit micro-controller
(8051 type). The micro-controller (µC), along with Bus bar heater: The third row displays the on/off
EPROM (Erasable programmable read only status of the bus bar heater control. When on the
memory), RAM (Random access memory), digital, computer signals the heater control to output 10%
serial and analog I/O are located on the uB (micro- power to the bus bars. This is useful for adjusting a
controller board). Most JFTOT application specific new power control. At 10% the heater controller
electronics are located on the interface board (such should output about 2 to 3 VAC. If not, the BIAS on
as thermocouple and pressure amplifiers, pulse the heater control can be adjusted. The GAIN
counters and real-time clock with date).The interface adjustment is made while running a JFTOT test. At
board also contains a series of test points for measur- 260°C the % power should be about 68% (+/- 10%).
ing power and signal voltages. A display interface Bypass valves: The fourth row displays the open/
board provides connection to the display, keypad and closed status of the bypass valves. Press F2 to open
alarm. Views are provided of the uB (Figure 6.1), or close the valves. BP1: is the status of the valve for
interface board (Figure 6.2), display interface board ∆P 1, and BP2: is the status of the valve for ∆P 2.
(Figure 6.3), layout of the keypad (Figure 6.4), list of The possible status displays are OPEN, CLOSED,
test points (Tables 6.1 and 6.2), and pin-out of and ----- (dashed indicate valve moving, not open or
connectors (Tables 6.3, 6.4, 6.5, 6.6 and 6.7). closed).

6.2 MAINTENANCE MENU Drive pump: The fifth row displays the status of the
drive pump. Depending on the status of the pump,
The maintenance menu is very useful for operating one or two of three different keys may be available
and viewing many parts of the JFTOT. This is helpful to change the status of the pump:
for testing and troubleshooting various parts of the
JFTOT. Enter the maintenance menu by pressing F5 KEY EFFECT ON STATUS
in the Main Menu. F3 TURN ON PUMP TO GO UP

WARNING - Be careful when operating the F4 TURN OFF PUMP

JFTOT from the maintenance menu. Many of
F5 TURN ON PUMP TO GO DOWN
the limits and safeties are disabled when
operating the JFTOT from the maintenance The five possible pump status displays are:
menu. Only a qualified trained technician should
OFF
operate the JFTOT from the maintenance menu.
OFF (at top)
OFF (at bottom)
going up
going down
Status of printer: The sixth row displays the status
of the serial interface used for sending reports to the
Analog values: The top two rows display the four printer (or a computer). The JFTOT checks the
analog process values measured by the JFTOT. The status of the printer by monitoring pin 20 of the 25-pin
top row displays the “A/D count” values used by the printer connector. This connector provides a RS-232
computer. The second row displays the readings serial interface, DCE (data communication equip-
ment).

JFTOT II Service Manual Rev. C Page 43

6.3 RELAY MODULES 1. Measure voltage on pin 2 (+) and 3 (-), should be
+5.000 VDC ±0.005 VDC. If necessary, adjust
The computer controls and monitors the status of R77 on the interface board.
various parts of the JFTOT using many solid state
relays modules (SSRM). These relay modules plug 2. Measure voltage on pin 4 (+) and 3 (-), should be
into the relay board, mounted inside on the rear door +15.00 VDC. No voltage adjustment is provided.
control panel (see Figure 1.3). A status LED (light Check computer power supply.
emitting diode) is located next to each SSRM. The
following list describes the function of each SSRM 3. Measure voltage on pin 5 (+) and 3 (-), should be
and the meaning of the status LED. -15.00 VDC. No voltage adjustment is provided.
Check computer power supply.
SSR
Module
Description LED on =
4. Measure voltage on pin 8 (+) and 3 (-), should be
0 Control to close DP2 bypass valve CLOSE +12.00 VDC ±2.0 VDC. No voltage adjustment
1 Control to open DP2 bypass valve OPEN is provided. This check for shorts in the trans-
2 Monitor position of DP2 bypass valve CLOSED ducer or cable.
3 Monitor position of DP2 bypass valve OPENED
4 Control to close DP1 bypass valve CLOSE
5. Measure voltage on pin 12 (+) and 3 (-), should
5 Control to open DP1 bypass valve OPEN
be -12.00 VDC ±2.0 VDC. No voltage adjust-
ment is provided. This check for shorts in the
6 Monitor position of DP1 bypass valve CLOSED
transducer or cable.
7 Monitor position of DP1 bypass valve OPENED
8 Control air pump on/off ON 6. Measure voltage on pin 7 (+) and 3 (-), should be
9 Control drive pump directon up/down DOWN -5.000 VDC ±0.5 VDC. If not but voltage in step
10 Monitor if drive pump is at bottom AT BOTTOM 5 is correct then the interface board is defective
11 Monitor if drive pump is at top AT TOP (U7).
12 Control heater power on/off ON
13 Control drive pump motor power on/off ON
7. Measure voltage on pin 6 (+) and 7 (-), should be
14 Monitor if heater power is on/off ON
+10.00 VDC. If necessary, adjust R17 on the
15 Monitor if drive pump power is on/off ON
interface board.
8. Measure voltage on pin 10 (+) and 11 (-), should
NOTE: The JFTOT-240 uses all SSRM, 0 through
be +10.00 VDC. This should be the same voltage
15. The JFTOT-230 uses only SSRM 4 through
as step 7. If not, there is an open in cable to
15.
transducer.

6.4 VOLTAGE CHECKS FOR PRESSURE 9. For system pressure only: Measure voltage on
TRANSDUCERS pin 33(+) and 34 (-), should be 0 to about
20mVDC. This voltage is the signal from the
The pressure transducers (system pressure and pressure transducer. 0mV = no pressure (0 psig),
differential pressure) are powered by 10.0 VDC. If 20mV = high pressure (500 psig). If you have a
this voltage is not correct, then the pressure signal millivolt source, you can input a millivolt signal to
output to the uB will be in error by the same percent- see if the pressure display is correct.
age. If dP standardization has shown the dP reading
to be in error by more than 20% (recheck to make 10. For dP only: This voltage is the signal from the
sure there is no air in the lines first) the 10.0 VDC dP transducer. 0mV = no pressure (0 mmHg),
excitation voltage may be incorrect. Measure volt- 20mV = high pressure (275 mmHg). If you have
ages on the interface analog test points (see Table a millivolt source, you can input a millivolt signal
6.1), using a good digital voltmeter. to see if the pressure display is correct.

Page 44 JFTOT II Service Manual Rev. C

6.5 CHECKING DRIVE PUMP FLOW The signal from the magnetic tach sensor can be
RATE measured on the interface board digital test points
(DTP) between pin 9 and pin 8 (ground). The
The drive system consists of a 90VDC motor with frequency is determined by:
gear reduction turning a screw. The screw pushes a
piston in the fuel reservoir, forcing fuel through the frequency = flowrate(mL/min) x 28.07
system. A 30 tooth gear, is attached to the motor for example, at 3.0mL/min:
shaft. A magnetic sensor, mounted on the motor next
to the gear, generates a pulse as each tooth of the frequency = 3.0 x 28.07 = 84.2Hz
gear passes. At 3.0mL/min the motor turns at
NOTE - the magnetic sensor signal voltage level
168.4RPM generating a sensor signal of 84.2Hz
varies with frequency (motor RPM). As the fre-
(about 1Vp-p). The computer measures the fre-
quency increases the voltage increases. At 3.0mL/
quency of the sensor using a 5.859KHz reference
min (84.2Hz) the voltage measures about 0.3VAC
(6Mhz/1024). The computer determines if the motor
(0.9Vp-p). The signal waveform is triangular.
RPM is correct and makes adjustments if necessary.
The computer controls the motors speed by varying If the magnetic tach sensor is not generating a signal,
the 0-1.2VDC control signal to the motor speed the sensor or wiring may be defective.
controller. The motor controller inputs the 0-1.2VDC
control signal and outputs 0-90VDC to power the 1. Check the magnetic tach sensor:
motor. The voltage to the motor can be changed as • Disconnect the 2-pin connector next to the
required to maintain a constant RPM, and therefore a motor.
constant flowrate.
• Measure the resistance across the 2 pins
To check the flowrate, measure the volume of water (white and black wires) to the magnetic
displaced during a test. The flowrate is calculated by sensor.
dividing the test time into the volume measured. For
• The resistance should be 300 ohms +/-150.
example, measuring 450mL from a 150 minutes test
yields 3.0mL/min. Allowable tolerance is 10% for • If the resistance is out of tolerance the
ASTM but the JFTOT should maintain a flowrate sensor is defective and must be replaced.
within 0.2mL/min. • Reconnect the 2-pin connector
If the flowrate is not correct, only the mechanical 2. Check the magnetic tach sensor wiring to
components can be adjusted. There are no adjust- computer:
ments to the electronics.
• Disconnect the 2-pin connector next to the
• The magnetic sensor can be adjusted closer to the motor.
motor gear to ensure all 30 teeth generate a pulse.
• Measure the resistance between red wire
• The drive belt can be adjusted to ensure it does not
and DTP pin 9. The resistance should be
slip on the drive pulleys. The belt and pulleys must
about 0 ohms. If not, the wiring is open and
be dry (no lubricant or fuel).
must be repaired.
• The reservoir ID, lipseal, and lines can be checked
for proper seal and no leaks. • Measure the resistance between red wire
and DTP pin 8. The resistance should be
If the magnetic sensor is not adjusted correctly the above 100K ohms. If not, the wiring is
calculated flowrate will be high. If the drive belt slips shorted and must be repaired.
or there is a fuel leak the calculated flowrate will be
low. • Measure the resistance between black wire
and DTP pin 8. The resistance should be
The electronic signals can be checked to ensure about 0 ohms. If not, the wiring is open and
proper operation. must be repaired.
• Reconnect the 2-pin connector

JFTOT II Service Manual Rev. C Page 45

The 5.859KHz reference can be measured on DTP • Turn off the drive motor then check and re-adjust
between pin 5 and pin 8 (ground). The waveform is the clearance. If the maximum clearance is still
5V logic pulse stream 50% duty cycle. more than 0.006" continue filing. If the clearance is
0.006" (0.15mm) or less then the clearance is
6.6 CHECKING AND ADJUSTING THE correct. Clean the motor and JFTOT of metal
DRIVE PUMP SPEED CONTROL filings.
SENSOR (TACH SENSOR). 5. Reinstall the drive pump and test the fuel flow
rate to verify operation.
The JFTOT-II flow rate is measured and controlled
by a magnetic speed sensor mounted on the pump
drive motor. The sensor is located next to a gear 6.7 MOTOR SPEED CONTROL
which is mounted on the drive motor shaft, see Figure DO NOT adjust the motor speed control. If the
6.5. The sensor generates a pulse signal as each control has been tampered with, adjust the control
tooth of the gear passes. The amplitude of the pulse back to the correct positions:
depends on the clearance distance between the
sensor and gear. If the distance is too great the signal • Switch settings: SW501 = 115V, SW502 = 115V,
may be too low to be measured by the computer. SW503 = 90V, SW504 = ARM FB. (Older controls
This sensor must be adjusted properly to maintain have SW504 = VOLTS and SW505 = ARM FB.)
accurate fuel flow rate. Check the flow rate using • Trimmer Pot settings: ACCEL = full CCW,
the procedure in the JFTOT Users Manual. If the DECEL = full CCW, CURRENT LIMIT = 12
flow rate is in error by more than 5% then perform O’clock (center), IR COMP = 10 O’clock (1/3 turn
the following to check and adjust the sensor. from CCW), TACH VOLTS = any setting (not
used).
1. You may find is easier to unbolt the drive pump
and move it where you can reach it. Leave the • To adjust MAX and MIN SPEED:
pump inside the back of the JFTOT because you 1. Turn power on. From Maintenance Menu, start
need to leave the electrical connector attached. Drive going up. Make sure that the system
pressure is vented.
2. Check the distance between the sensor and the
gear. A clearance of 0.003" (0.08mm) is best, 2. Measure the voltage between S1 and S2 on the
more than 0.006"(0.15mm) is too large. You speed controller. Adjust the MAX SPEED pot
want to get the sensor as close as you can for 0.45 VDC.
without touching the gear. Turn the gear by-hand
to check that the sensor does not touch the gear. 3. Use a jumper to short S1 to S2. Adjust the MIN
SPEED so the gear on top of drive motor just
3. If necessary, loosen the nuts securing the sensor barely turns. Then remove the jumper shorting
to the bracket. Adjust the sensor as close to the S1 to S2.
gear as possible with touching the gear. Tighten
the nuts and re-check the proper clearance. 4. Repeat steps 2 and 3.

4. If the clearance varies when the gear is turning, 6.8 INTERFACE BOARD FOR JFTOT-II
then the gear has a “wobble”. If the maximum S/N 200 TO 245.
clearance exceeds 0.006" (0.15mm) then reduce
the amount of wobble: Some of the earlier JFTOTs used a motor speed
control with a 0-5 VDC input control range. The
• Turn on the JFTOT and turn the pump to go
interface board was designed to output a 0-1.2
up.
VDC control range. For those JFTOTs that use
• Use a knife sharpening stone or small mill file the 0-5 VDC speed control, a resistor (R54, 1.5K
and lightly touch the gear while spinning. File OHM) was cut on the interface board to expand
down the high spots on the gear. its output control range to 0-5 VDC. If the motor
speed control needs to be replaced, you will

Page 46 JFTOT II Service Manual Rev. C

 receive a new unit with 0-1.2 VDC input control (“ERROR: HEATER TOO LONG AT MAX
range. A motor speed control with 0-1.2 VDC OUTPUT”). The maximum % power output can be
input control range will work on a modified calculated using the temperature setpoint (°C) and
interface board(after adjusted per instructions for flowrate (mL/min).
Motor Speed Control), but a motor speed control
MAX % OUTPUT= 80 + (0.124 x (setpoint-260)) +
with 0-5 VDC input control range will NOT work
(1.814 x (flowrate-3.0))
on a un-modified interface board.
For example: the MAX % OUTPUT = 80% for
6.9 REPLACING PRESSURE TRANSDUC- 260°C and 3.0 mL/min.
ERS Note: The maximum value for MAX % OUTPUT is
Whenever a system pressure or ∆P transducer is 100%.
replaced, the computer must be adjusted to the new The % power readings at 260°C may differ from
calibration valves of the transducer. Two adjustments 68% by ± 10% due to variations in line voltage,
are required. cleanliness of bus bars (front and inside connections),
1. The ZERO reading must be adjusted on the and age of JFTOT. The % power reading will be
interface board. Make sure all internal fuels lines different for setpoints and flowrates other than 260°C
are liquid full. Remove all external fuel lines and and 3.0 mL/min respectively.
set the top selector valve to SYSTEM VENT. To adjust the % power, follow these instructions:
While displaying the Maintenance Menu adjust
the OFFSET trimmers to zero the corresponding 1. Turn power off and unplug power cord. Remove
transducer readings (372 computer valve = 0 rear cover from the JFTOT.
pressure).
2. Locate the SCR power control on the top inside
surface of the cabinet (see Figure 6.6).
3. Locate the GAIN adjustment trimmer (see
Figure 6.12) DO NOT adjust the BIAS trimmer.
4. Setup and run a D3241 or custom test at 260°C
2. The CALIBRATION VALVE listed on the and 3.0mL/min.
Certification Record provided with the transducer
(multiplied by 10) must be entered into the CAUTION: there is hazardous voltage
computer SYSTEM SETUP Menu (press F8 in exposed on the power control and
Main Menu). surrounding components.

6.10 CHECKING AND ADJUSTING THE

5. After the test has been running about 15 minutes,
SCR POWER CONTROL slowly adjust the GAIN trimmer until the dis-
The ideal adjustment provides 68% power when played % power is 68% (±2%).
running a D3241 test at 260°C. However, a 260°C
6. When finished, terminate the test, turn power off,
D3241 test will run properly with readings of 58% to
and unplug the power cord. Replace the rear
78% power. Do not let the % power reach the
cover on the JFTOT.
maximum power output or after 20 seconds the test
will abort and a error message will be displayed 7. The JFTOT power control is now adjusted and
ready to run tests.

JFTOT II Service Manual Rev. C Page 47

6.11 PRINTER SPECIFICATIONS 6.12 COMPONENTS OF THE ELECTRI-
CAL SYSTEM
The JFTOT-II is supplied with a printer. The printer
is configured with the settings as shown below. For Detail views are provided to show the various
paper size other than 8.5" x 11", the page length may components of the electrical system including wire
be changed to fit the paper size desired. routing and other detail views of the electrical
system. These views are located near the end of this
section.

6.13 ELECTRICAL SCHEMATICS

Electrical schematics (64973, 3 pages) and block
diagram are provided at the end of this section for
reference.

Page 48 JFTOT II Service Manual Rev. C

 FIGURE 6.1 - µB (P/N 54719)

JFTOT II Service Manual Rev. C Page 49

 FIGURE 6.2 - INTERFACE BOARD (P/N 54700)

Page 50 JFTOT II Service Manual Rev. C

 FIGURE 6.3 - DISPLAY INTERFACE BOARD (P/N 54716)

JFTOT II Service Manual Rev. C Page 51

 FIGURE 6.4 - KEYPAD

Page 52 JFTOT II Service Manual Rev. C

 FIGURE 6.5 - DRIVE PUMP TACH SENSOR AND GEAR

JFTOT II Service Manual Rev. C Page 53

 TABLE 6.1 - INTERFACE BOARD ANALOG TEST POINTS (ATP), 40-PIN HEADER

Page 54 JFTOT II Service Manual Rev. C

 TABLE 6.2 - INTERFACE BOARD DIGITAL TEST POINTS (DTP), 10-PIN HEADER

TABLE 6.3 - P8 CONNECTOR PINOUT, uB POWER

TABLE 6.4 - P14 CONNECTOR PINOUT, DIGITAL INTERFACE

JFTOT II Service Manual Rev. C Page 55

 TABLE 6.5 - P15 CONNECTOR PINOUT, ANALOG INTERFACE

Page 56 JFTOT II Service Manual Rev. C

 TABLE 6.6 - P44 CONNECTOR PINOUT, DISPLAY SIGNAL

TABLE 6.7 - P45 CONNECTOR PINOUT, DISPLAY POWER

JFTOT II Service Manual Rev. C Page 57

 FIGURE 6.6 - WIRE ROUTING

Page 58 JFTOT II Service Manual Rev. C

 FIGURE 6.7 - DETAIL “T” DISPLAY CONNECTIONS - REAR VIEW
(COMPONENTS NOT SHOWN FOR CLARITY)

FIGURE 6.8 - DETAIL “A” DISPLAY

ASSEMBLY SIDE VIEW

JFTOT II Service Manual Rev. C Page 59

 FIGURE 6.9 - COMPUTER BOARD MOUNTING HARDWARE

Page 60 JFTOT II Service Manual Rev. C

 FIGURE 6.10 - INTERFACE BOARD CONNECTORS

FIGURE 6.11 - DETAIL “V” TRANSFORMER WIRE CONNECTION (90698)

JFTOT II Service Manual Rev. C Page 61

 FIGURE 6.12 - DETAIL “R” WIRING FOR LOW VOLTAGE TRANSFORMER & SCR

FIGURE 6.13 - DETAIL “U” FAN ASSEMBLY

Page 62 JFTOT II Service Manual Rev. C

 FIGURE 6.14 - ELECTRICAL BLOCK DIAGRAM

JFTOT II Service Manual Rev. C Page 63

 FIGURE 6.15 - ELECTRICAL SCHEMATIC

Page 64 JFTOT II Service Manual Rev. C

 FIGURE 6.16 - ELECTRICAL SCHEMATIC

JFTOT II Service Manual Rev. C Page 65

 FIGURE 6.17 - ELECTRICAL SCHEMATIC

Page 66 JFTOT II Service Manual Rev. C

7. TECHNICAL INFORMATION BULLETINS (TIBS)

Technical Information Bulletins (TIB) are used to

provide information on ALCOR products. Some of
the information contained in a TIB can include:
1. New information to help operate or maintain
equipment.
2. Reprinting information from manuals to help
operate or maintain equipment.

3. Provide new applications for existing equipment.

4. Provide safety information and warnings.
An index is available1 that provides a list of all TIBs.

1
A TIB Index may be obtained from ALCOR Petroleum Instruments
300 Bammel Westfield Road, Houston TX 77090 USA

JFTOT II Service Manual Rev. C Page 67

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Page 76 JFTOT II Service Manual Rev. C

 FOR:JFTOT-II
Technical Information Bulletin S/N 200 & UP
This information is supplied to you to inform you of a change or TIB 012 A
an upgrade pertaining to your piece of equipment.
PAGE 1 OF 7_

June 20, 2003

Adjusting SCR power controller in response to message

“HEATER ON TOO LONG AT MAX OUTPUT”

The JFTOT-II (models 230 and 240) have been built with two different SCR power controls. Use
the appropriate procedure for the SCR provided in your JFTOT.

JFTOT-230/240 S/N 200 to 476 with SCR P/N 83193

1. Open back of JFTOT cabinet. Attach an AC voltmeter to terminals on the low voltage
transformer, see Figure 1.
2. Turn on power. From MAIN MENU press F5 to go to MAINTENANCE MENU. Press F1 to
turn on heater. The voltmeter will show 0 volts then it should increase to about 10 or 12 volts
in about 15 seconds. Note: the computer will automatically turn off the heater after a short
period of time. If needed, press F1 again to check and adjust the voltage reading.
3. If the voltage reading does not approach 10 volts, then turn off the JFTOT and remove the two
plastic covers from the SCR power controller, see Figure 2. Do not disconnect any wires; let
the larger cover hang from the wires while performing any adjustments.
4. Locate the GAIN and BIAS trimming pots, see Figure 3.
5. Turn on power.
6. From MAIN MENU press F5 to go to MAINTENANCE MENU. Press F1 to turn on the
heater, then wait about 10 seconds before making any adjustments. The SCR power controller
has a SOFT START feature that causes the SCR to turn on slowly. Adjust the BIAS pot for 10
to 12 AC volts within 15 seconds. Adjusting the BIAS pot CW (clockwise when viewing the
end of the screw on the trimmer pot, see Figure 4) will increase the voltage.
7. Set-up the JFTOT to run a test at 260qC. Once the test has started and the temperature has
stabilized at 260qC, adjust the GAIN pot until the JFTOT displays a % POWER of 68%.
Adjusting the GAIN pot CCW (counter-clockwise when viewing the end of the screw on the
trimmer pot, see Figure 4) will increase the displayed % power.
8. The BIAS and GAIN adjustments effect each other. Therefore, perform steps 6 and 7 at least
twice to make sure the proper voltages are obtained.
9. When finished making the adjustments, replace the covers on the SCR and the back on the
JFTOT.

NOTE: If you measure no voltage at the low voltage transformer, then check for 120 volts AC on
the SCR input terminals 2 and 3. If there is 120 volts at the SCR input but there is no voltage at
the low voltage transformer, then replace the SCR.

NOTE: During an ASTM test (set-up for 260qC), the Heater will come on to 80% and the
temperature will rise. At about 170qC the % power will begin to drop. Within one minute the
temperature should stabilize at the 260qC set point and the % power should read about 60% to
70%.

JFTOT II Service Manual Rev. C Page 77

 FOR:JFTOT-II
Technical Information Bulletin S/N 200 & UP
This information is supplied to you to inform you of a change or TIB 012 A
an upgrade pertaining to your piece of equipment.
PAGE 2 OF 7_

JFTOT-230/240 S/N 477 and later with SCR P/N 83201

1. Open back of JFTOT cabinet. Attach an AC voltmeter to terminals on the low voltage
transformer, see Figure 5.
2. Locate the GAIN trimming pot, see Figure 6.
3. Turn on power.
4. Set-up the JFTOT to run a test at 260qC. Once the test has started and the temperature has
stabilized at 260qC, adjust the GAIN pot until the JFTOT displays a % POWER of 68%. Do
not adjust the BIAS pot. You must use a small screwdriver with a slotted tip no larger than
3/32” wide (2.3 mm). The trimming pot is about 3/8” (9mm) inside the hole in the plastic
housing.
5. When finished making the adjustments, replace the back on the JFTOT.

NOTE: If you measure no voltage at the low voltage transformer, then check for 120 volts AC on
the SCR input terminals 2 and 3. If there is 120 volts at the SCR input but there is no voltage at
the low voltage transformer, then replace the SCR.

NOTE: During an ASTM test (set-up for 260qC), the Heater will come on to 80% and the
temperature will rise. At about 170qC the % power will begin to drop. Within one minute the
temperature should stabilize at the 260qC set point and the % power should read about 60% to
70%.

Page 78 JFTOT II Service Manual Rev. C

 FOR:JFTOT-II
Technical Information Bulletin S/N 200 & UP
This information is supplied to you to inform you of a change or TIB 012 A
an upgrade pertaining to your piece of equipment.
PAGE 3 OF 7_

JFTOT II Service Manual Rev. C Page 79

 FOR: JFTOT-II
Technical Information Bulletin S/N 200 & UP
This information is supplied to you to inform you of a change or TIB 012 A
an upgrade pertaining to your piece of equipment.
PAGE 4 OF 7_

Page 80 JFTOT II Service Manual Rev. C

 FOR:JFTOT-II
Technical Information Bulletin S/N 200 & UP
This information is supplied to you to inform you of a change or TIB 012 A
an upgrade pertaining to your piece of equipment.
PAGE 5 OF 7_

JFTOT II Service Manual Rev. C Page 81

 FOR:JFTOT-II
Technical Information Bulletin S/N 200 & UP
This information is supplied to you to inform you of a change or TIB 012 A
an upgrade pertaining to your piece of equipment.
PAGE 6 OF 7_

Page 82 JFTOT II Service Manual Rev. C

 FOR:JFTOT-II
Technical Information Bulletin S/N 200 & UP
This information is supplied to you to inform you of a change or TIB 012 A
an upgrade pertaining to your piece of equipment.
PAGE 7 OF 7_

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JFTOT II Service Manual Rev. C Page 85
Page 86 JFTOT II Service Manual Rev. C
JFTOT II Service Manual Rev. C Page 87
Page 88 JFTOT II Service Manual Rev. C
 FOR:JFTOT-II
Technical Information Bulletin Model 230/240
This information is supplied to you to inform you of a change or TIB 015
an upgrade pertaining to your piece of equipment.
PAGE 1 OF 1_

January 30, 2004

SERVICING COOLANT SYSTEM

JFTOT-II (model 230 & 240)

The JFTOT-II has a coolant pump to pump a coolant through the bus bars. The JFTOT-II uses
one of two pumps. S/N 1-199 (with blue & white cabinet) uses a 120VAC pump p/n 60092 and
S/N 200 and up (SS cabinet) uses a 24VDC pump p/n 60115.

If a pump fails and needs to be replaced, then certain operations should be performed to insure
that the new pump does not fail prematurely.

1. Check the depth of the cooling jets inside the bass bars. If the jets are too deep, a high back
pressure will form causing the pump to fail. The jets should be approximately ¼ inch from
end of the cavity in the bus bar. If the jets are too deep, you can remove some of the tubing
or file the end down at a 45 degree angle to give proper depth. The Swagelok fittings are not
adjustable once set so the tubing will have to be modified.

2. The coolant system should be flushed and refilled with new coolant after any work is
performed. Completely drain and flush the cooling system. Use water to remove any
contaminates (grit and other particulate) that may have found its way into the system. Drain
the water, install the new pump, then refill system with new coolant (50/50 mixture of water
and ethylene glycol “antifreeze”).

JFTOT II Service Manual Rev. C Page 89

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Page 90 JFTOT II Service Manual Rev. C