Mu - Jftot 230 Mark III

JFTOT 230
MARK III
JET FUEL THERMAL OXIDATION TESTER
USER’S MANUAL
PN: AL-59322
Revision B
8824 Fallbrook Dr. • HOUSTON, TEXAS 77064 USA

TELEPHONE: 800-444-TEST or 281-580-0339 • FAX: 281-580-0719
sales@paclp.com•www.paclp.com
THIS MANUAL CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION…
…which is the property of PAC. This manual and all information disclosed herein shall not
be used to manufacture, construct, or fabricate the goods disclosed herein; shall not be
exploited or sold; shall not be copied or otherwise reproduced in whole or in part and shall
not be revealed or disclosed to others or in any manner made public without the express
written permission of PAC.
Copyright ©2006, by PAC, Houston, Texas.

Printed in the United States of America
All rights reserved.
Contents of this publication may not be reproduced in any form
without permission of the copyright owner.
5.18.06
MS Windows®, MS Windows® X P, and MS Windows Professional® are registered trademarks of Microsoft Corp.
REVISION HISTORY
Rev Revision Description Rev Date
A Original Release 2-28-06
B Changes to Fuses and Coolant Pump Added VTDR Option. 5-18-06
ALCOR JFTOT III Users Manual
TABLE OF CONTENTS
ABOUT THIS MANUAL......................................................................................................... ii
Abbreviations and Symbols...................................................................................................................iii
Proper Use and Safety ........................................................................................................................... iv
STANDARD LIMITED WARRANTY.......................................................................................... v
SECTION 1: INTRODUCTION
SECTION 2: INSTALLATION
SECTION 3: OPERATION
SECTION 4: CALIBRATION
SECTION 5: MAINTENANCE AND SERVICE
File Name: JFTOT III User’s Manual Part No. 59322

Rev B i
ABOUT THIS MANUAL

This manual has been written for the JFTOT 230 MARK III Jet Fuel Thermal Oxidation
Tester (JFTOT III). Until superseded, this manual may be used for all JFTOT III
instruments. One User’s Manual is provided with each JFTOT III instrument.
A Quick-Start Guide is included in Section 3 “Operation” and is provided as a laminated

page for access during a test.
The following graphic symbols are used in the JFTOT III to inform the user of possible
hazardous areas on the JFTOT III. The first three symbols are used in this user’s manual to
inform the reader of hazardous conditions during the performance of a procedure.
Symbol Definition
This symbol (exclamation point in a triangle) indicates a general Caution or

Warning. A Caution alerts you to information that is important for protecting the
equipment and performance. A Warning alerts you to information that is important
for protecting yourself, others and equipment from damage.
This symbol (a lightning bolt in a triangle) indicates an electrical shock hazard.

Inside the JFTOT III are exposed live voltage circuits. The JFTOT III should be
opened only by qualified service personnel. To prevent electrical shock hazard DO
NOT make contact with electrical components or allow liquids to be spilled onto
electrical components.
This symbol (three wavy lines over a straight line in a triangle) indicates a hot
surface. During operation, the JFTOT III surfaces near the heater test section get
hot. To prevent burns, exercise caution when operating the JFTOT III. Do NOT
open the protective cover while the instrument is in use.
PROTECTIVE GROUND CONDUCTOR: indicates earth ground wire or

terminal
DP DIFFERENTIAL PRESSURE (DP): indicates pressure across the filter (reported in

mmHg consistent with the original JFTOT kerosene/mercury manometer) The
JFTOT displays DP as “dP”.
Part No. 59322 File Name: JFTOT III User’s Manual

ii Rev B
ABBREVIATIONS AND SYMBOLS
NOTE: The JFTOT 230 MARK III Jet Fuel Thermal Oxidation Tester is commonly
referred to as the “JFTOT III”.
The User’s Manual contains certain abbreviations and symbols as described in the
following list.
Abbreviation Unit
A Amps
° degrees
g grams
h hours
Hz Hertz
JFTOT Jet Fuel Thermal Oxidation Tester
JFTOT III JFTOT 230 MARK III
K kilo = x 103
L liters (mL = milliliters)
M mega = x 106
m meter (mm = millimeter, cm = centimeter)
min minutes
mLpm milliliters per minutes
Pa Pascal = Newton/meter2
PCB Printed Circuit Board
psi pounds force/inch2 (psig = psi gauge)
rms root mean square
s seconds
V Volts
VA Volt-amperes
W Watts

Rev B iii
PROPER USE AND SAFETY
The JFTOT III is intended for indoor laboratory use only. This equipment has been
designed and tested in accordance with EN 61010, “Safety Requirements for Electrical
Equipment for Measurement, Control, and Laboratory Use.” Use of this product in an
unsafe environment or in a manner not specified may impair the protection and
performance designed into the equipment.
This user’s manual contains information, warnings, and cautions that must be followed to
ensure safe operation and to maintain the equipment in safe operating condition. Safety
glasses should be worn by the operator and anyone in the vicinity of the equipment for
protection from splashed materials. Tests performed with this equipment may involve
hazardous materials.
This manual does not purport to address all safety concerns associated with the operation
of the JFTOT III. It is the responsibility of the user of this equipment to establish
appropriate safety and health practices and to determine applicability and limitations prior
to use.
CAUTION: Do not use this equipment in a hazardous atmosphere. Do not use this
equipment with hazardous materials for which the equipment is not
designed. Protection provided by this equipment may be impaired if used
with accessories not provided or recommended by the manufacturer or used
in a manner not specified by the manufacturer.
Servicing and repair should be performed only by qualified personnel. Disconnect the
equipment from the power source when servicing or replacing electrical components.
Service replacement parts and technical assistance for this equipment may be obtained
from:
PAC
8824 Fallbrook Dr.
Houston, TX 77064
Tel: 281-580-0339 or 800-444-TEST
Fax: 281-580-0719
sales@paclp.com
www.paclp.com

iv Rev B
STANDARD LIMITED WARRANTY

OF
PETROLEUM ANALYZER COMPANY, L.P
I. Limited Warranty
1. Limited Warranty. Petroleum Analyzer Company, L.P. (“PAC”) offers a limited warranty on each of its
products against failure due to defects in material and workmanship for a period ending the earlier of
(i) eighteen (18) months from the date of the invoice relating to the sale of the product and (ii) twelve
(12) months from the date of installation of the product (collectively, the “Initial Warranty”). During
the Initial Warranty, PAC offers a limited warranty against failure due to defects in material and
workmanship on each part of a product repaired or replaced by an authorized service person for a period
ending the later of (a) the remaining term of the Initial Warranty of the product and (b) ninety (90) days
from the date of such repair or replacement. After expiration of the Initial Warranty, PAC offers a
limited warranty against failure due to defects in material and workmanship on each part of a product
repaired or replaced by an authorized service person for a period ending ninety (90) days from the date
of such repair or replacement. PAC further offers a limited warranty that the products and parts it sells
will conform to PAC’s written specifications therefor. The foregoing limited warranties cover parts and
labor only and PAC does not warrant and will not reimburse the buyer of its products (“Buyer”) for any
costs relating to the access by service persons of PAC to the product at issue. The foregoing limited
warranties cover only the repair or replacement of defective parts and such determination will be in the
sole discretion of PAC. In its sole discretion, PAC may make repairs or replacements under these limited
warranties with either new or refurbished parts. To the extent Buyer’s product cannot be remedied
under these limited warranties through repair or replacement of parts, Buyer may return the product for
a refund of the purchase price, less a reasonable reduction in such purchase price equal to the
depreciation expense incurred by Buyer relating to such product. The limited warranties of this
Section I.1. are further subject to those warranty exclusions set forth below in Section I.2.
2. Limited Warranty Exclusions. EXCLUDING THE WARRANTIES PROVIDED FOR IN SECTION I.1., PAC
PROVIDES ALL PRODUCTS TO BUYER “AS-IS,” WITHOUT ANY OTHER WARRANTY OF ANY KIND. PAC
DISCLAIMS ANY AND ALL EXPRESS OR IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A
PARTICULAR PURPOSE AND NON-INFRINGEMENT OF THE INTELLECTUAL PROPERTY OF OTHERS. PAC
MAKES NO WARRANTY, EXPRESS OR IMPLIED, AS TO THE DESIGN, SALE, INSTALLATION OR USE OF ITS
PRODUCTS. PAC’S WARRANTIES WILL NOT BE ENLARGED BY, NOR WILL ANY OBLIGATION OR LIABILITY
OF PAC ARISE DUE TO PAC PROVIDING TECHNICAL ADVICE, FACILITIES OR SERVICE IN CONNECTION
WITH ANY PRODUCT. There is no warranty by PAC with respect to any product’s: (i) uninterrupted or
error-free operation; (ii) actual performance, other than the product’s capability to meet PAC’s
specifications therefor; (iii) removal or installation from a worksite or process; (iv) electronic
components or associated accessories (including without limitation circuit boards and integrated
circuits); (v) maintenance (including without limitation gasket and seal replacements, adjustments,
minor repairs and other inspection requirements, preventative or otherwise); (vi) use under
inappropriate conditions or not in accordance with operating instructions; or (vii) use in connection
with the operation of a nuclear facility. There is no warranty for labor expenses associated with field
repairs or the repair or replacement of defective parts in the engine or power unit of any product if such
product has been in the possession of the owner or operator for greater than twelve (12) months. There
is no warranty for products determined to be, in PAC’s sole discretion, damaged as a result of (a) misuse,
neglect or accident; (b) improper application, installation, storage or use; (c) improper or inadequate
maintenance or calibration; (d) operation outside of the published environmental specification;
(e) improper site preparation or maintenance; (f) unauthorized repairs or replacements;
(g) modifications negligently or otherwise improperly made or performed by persons other than PAC;
(h) Buyer-supplied software or supplies; (i) use in conjunction with or interfacing with unapproved
accessory equipment; (j) use of ABC-style or dry powder fire suppression agents; or (k) leaked sample
materials. To the extent a PAC product is used in connection with the operation of a nuclear power

Revision B v
facility, Buyer agrees to indemnify and hold PAC harmless from any and all actions, claims, suits,
damages and expenses arising from such use. PAC provides no warranty on the oral representations
made by its personnel while they are attempting to assist Buyer in the operation of a product. This
Standard Limited Warranty does not apply to items consumed by the products during their ordinary use,
including but not limited to fuses, batteries, paper, septa, fittings, screws, fuses, pyrolysis, dryer or
scrubber tubes, sample boats, furnaces or UV lamps.
3. Non-PAC Products. PAC does not in any way warrant products it does not manufacture except to the
extent the warranty of the manufacturer of the product at issue passes through or is otherwise assigned
to PAC. If a manufacturer warranty is so assigned to PAC, PAC will only be bound to comply with the
length of time associated with such warranty. All other terms of such warranty will be governed by this
Standard Limited Warranty and PAC’s General Terms and Conditions incorporated herein by reference.
4. Expenses on Non-Warranty Work. All repairs or replacements by PAC after the expiration of any
applicable limited warranty period will be performed in accordance with PAC’s standard rate for parts
and labor. Further, if upon PAC’s inspection and review, PAC determines the condition of the products
is not caused by a defect in PAC’s material and workmanship, but is the result of some other condition,
including but not limited to damage caused by any of the events or conditions set forth in Section I.2.,
Buyer shall be liable for all direct expenses incurred by PAC to conduct the inspection and review of the
product.
5. Exclusive Remedy. THE FOREGOING LIMITED WARRANTY CONSTITUTES BUYER’S EXCLUSIVE REMEDY
WITH RESPECT TO PRODUCTS SOLD BY PAC AND PAC’S LIABILITY SHALL BE EXCLUSIVELY LIMITED TO
THE WRITTEN LIMITED WARRANTY SPECIFIED HEREIN. No employee, representative or agent of PAC is
authorized to either expressly or impliedly modify, extend, alter or change any of the limited warranties
expressed herein to Buyer.
6. Procedure and Costs. All limited warranty claims must be made in writing promptly following discovery
of any defect. Buyer must hold defective products for inspection by PAC. If requested by PAC, Buyer
must send the product to PAC for inspection. Any such returns by Buyer will be at Buyer’s expense and
Buyer will remain liable for any loss of or damage to the product during such product’s transportation to
PAC. No products will be sent to PAC for inspection unless PAC has authorized Buyer to do so.
7. Terms and Conditions. PAC’s General Terms and Conditions are incorporated herein by reference and
Buyer accordingly agrees to be bound by the terms thereof.
II. Limitations on PAC Liability

1. In General. BUYER AGREES PAC SHALL NOT BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL,
PUNITIVE OR CONSEQUENTIAL DAMAGES, INCLUDING LOST PROFITS, LOST SAVINGS OR LOSS OF USE,
WHETHER BUYER’S CLAIM IS BASED IN CONTRACT, TORT, WARRANTY, STRICT LIABILITY OR OTHERWISE,
WHICH BUYER MAY SUFFER FOR ANY REASON, INCLUDING REASONS ATTRIBUTABLE TO PAC. Buyer
agrees these limitations on PAC’s liability are reasonable and reflected in the amounts charged by PAC
for its products.
2. Force Majeure. This Standard Limited Warranty does not cover and PAC shall not be liable for either
direct or consequential damage caused, either directly or indirectly, as a result of: (i) any act of God,
including but not limited to natural disaster, such as floods, earthquakes, or tornadoes; (ii) damages
resulting from or under the conditions of strikes or riots, war, damages or improper operation due to
intermittent power line voltage, frequency, electrical spikes or surges, unusual shock or electrical
damage; or (iii) accident, fire or water damage, neglect, corrosive atmosphere or causes other than
ordinary use.
3. Limitation on Warranty Claims. Prior to any obligation of PAC to perform any limited warranty service
as set forth herein, Buyer must have: (i) paid all invoices to PAC in full, whether or not they are
specifically related to the product at issue; and (ii) notified PAC of the limited warranty claim within
sixty (60) days from the date Buyer knew or had reason to know of the defect.
PAC • 8824 Fallbrook Dr. • Houston, Texas • 77064 • USA

Phone 800-444-TEST or 281.580.0339 • Fax 281.580.0719
sales@paclp.com • www.paclp.com

vi Rev B
Warranty Registration Certificate Form
Thank you for choosing our line of analyzers. In order to serve your needs during the life of this
instrument, please complete the sections in the Warranty Registration Certificate form and return a
copy to PAC FAX or Email attachment to:
Fax 281.580.0719
sales@paclp.com
Contact Information:
Customer Name Phone Number
Mailing Address Fax Number
E-mail Address
Instrument Information:
Model Number
Serial Number
Installation Date
PAC Representative
Additional Remark:
www.paclp.com
Phone 800-444-TEST or 281.580.0339

Revision B vii
JFTOT 230
MARK III
USER’S MANUAL
SECTION 1: INTRODUCTION
PN: AL-59322
Revision B

…which is the property of PAC. This manual and all information disclosed herein shall
not be used to manufacture, construct, or fabricate the goods disclosed herein; shall not
be exploited or sold; shall not be copied or otherwise reproduced in whole or in part
and shall not be revealed or disclosed to others or in any manner made public without
the express written permission of PAC.

05.18.06
REVISION HISTORY
B Changes to Fuses and Coolant Pump. Added VTDR Option. 05-18-06
ALCOR JFTOT III Users Manual Section 1: Introduction
SECTION 1: TABLE OF CONTENTS

SECTION 1: INTRODUCTION................................................................................................1
1.1 OVERVIEW ...................................................................................................................1
1.1.1 Benefits and Features .............................................................................................................. 2
1.1.2 Specifications ........................................................................................................................... 2
1.1.3 Available Certifications ........................................................................................................... 3
1.1.4 Methods .................................................................................................................................... 3
1.1.5 Other Required Equipment..................................................................................................... 3
1.1.6 Software Overview .................................................................................................................. 4
1.1.7 JFTOT III Simplified Block Diagram ..................................................................................... 5
1.2 FUNCTIONAL OVERVIEW ..........................................................................................6
1.3 THEORY OF OPERATION...........................................................................................7
1.4 COMPONENT DESCRIPTIONS....................................................................................8
1.4.1 Front Panel............................................................................................................................... 8
1.4.1.1 Sample Container Area.................................................................................................... 8
1.4.1.2 Heater Tube Test Area.................................................................................................... 9
1.4.1.3 Drive Pump .................................................................................................................... 10
1.4.1.4 Main Screen Display...................................................................................................... 10
1.4.2 Back Panel .............................................................................................................................. 11
SECTION 1:
INTRODUCTION
1.1 OVERVIEW
The JFTOT 230 Mark III Jet Fuel Thermal Oxidation Tester (JFTOT III) is a fully
integrated bench-top instrument that, along with a visual or video tube rater, provides
everything needed to safely study the thermal oxidation of any petroleum-based liquid
fuel. The instrument is normally used in a batch mode where a fuel sample is held in a
reservoir and pumped across a heated metal surface to a second reservoir.
The purpose of the JFTOT III system is to measure formation of deposits from jet fuel
when heated in the presence of dissolved oxygen and a metal surface. The deposits
can then be measured and compared against a standard to determine the degree of fuel
degradation due to thermal oxidation.
The JFTOT III has been significantly improved to allow simplified setup and user-
friendly operation through a standard MS Windows® based PC touch-screen and
menu-driven JFTOT III software.
The JFTOT III (Figure 1-1) can be set for either 115 or 230 VAC power.
FIGURE 1-1
JFTOT III
File Name: JFTOT III User’s Manual Part No. AL-59322

Revision B Page 1-1
1.1.1 BENEFITS AND FEATURES

The JFTOT III instrument has the following benefits and features:
• Provides safe, semi-automatic method for testing the oxidation properties of jet
fuel.
• MS Windows® XP Professional® OS driven flat panel touch-screen display for
easily selecting modes of operation and parameters. Test results and meter
indications are also displayed on the touch screen.
• Critical operating parameters such as sample flow, pressures and temperatures
are monitored and controlled.
• Automatic venting and purging
• Two USB ports for connection to user defined external devices
• Quick configuration for 115 VAC (50/60 Hz) or 230 VAC (50/60 Hz) power
• No environmentally hazardous wastes
• Low maintenance
1.1.2 SPECIFICATIONS
The ALCOR JFTOT III is designed to conform to the following specifications:
• Man Machine Interface (MMI): Front panel mounted Pentium III PC with
Touch Screen LCD capable of operating as a standard PC through MS
Windows® XP Professional® programs; 12-inch mini-keyboard; mouse; 40-GB
hard drive; CD-ROM drive; speaker ports, serial and USB ports.
• Heater-Tube temperature setpoint range: 100°C to 380°C
• Fuel sample flow-rate range: 0.001mL/min to 9.999 mL/min
• Flow rate accuracy: ±2%
• Pump: HPLC, Dual Head SS
• Fuel Sample Volume Capacity: Unlimited
• Thermocouple type: K (Chromel/Alumel)
• Thermocouple temperature range: 0°C to +500°C
• DP range: 0 to +280 mmHg (automatically bypassed at +250 mmHg)
• Operating system pressure range: 3.45 MPa (500psig) ± 10%
• Automatic test numbering: 1 to n (n=hard drive capacity)
• Test time range: programmable 1 min. and up
• Fuel aeration timer: 6 minutes
• Aeration Flow rate: 1.5 L/Min (Green)
• Coolant flow rate: 10 Gal/Hr (Green)
• JFTOT III ambient temperature range: +10°C to +35°C (ASTM D 3241
test limited to +15°C to 32°C)
• Operating power voltage: 115VAC ±10% (for 85436-115V) single phase
or 230VAC ±10% (for 85436-230V) single phase
Part No. AL-59322 File Name: JFTOT III User’s Manual

Page 1-2 Revision B
1.1.2 Specifications (Continued)

• Operating power frequency: 50Hz or 60Hz ±5%
• Typical Idle power requirements: 220VA (JFTOT III without Printer)
• Typical operating power: 450VA (JFTOT III without Printer)
• Absolute maximum power: 670VA (JFTOT III without Printer)
• Printer interface: USB
• Dimensions:
• Width – 20 in (51 cm)
• Depth – 22.8 in (58 cm)
• Height – 29.4 in (75 cm)
• Weight: 180 pounds (82 Kg)
1.1.3 AVAILABLE CERTIFICATIONS

The JFTOT III can be compliant with the following regulatory standards.
• CE
1.1.4 METHODS
The following methods can be used for the JFTOT III.
• ASTM D3241
• IP 323
• ISO 6249
1.1.5 OTHER REQUIRED EQUIPMENT

The following items are not supplied with the JFTOT III but are required for normal
operation:
Table 1-1
JFTOT III Required Equipment:
# Item Part No
Visual Tuberator with ASTM Color Standard
115V 50/60 Hz AL-85417
or 230V 50/60 Hz AL-85418
1 or
Video Tube Deposit Rater with ASTM Color Standard
(Stand Alone) 115V or 230VAC 50/60 Hz AL-85501
(with Computer IF) 115V or 230VAC 50/60 Hz AL-85511
2 Printer with USB interface (USA only) or user-supplied printer
For optional equipment, see end of Section 5.8 in Maintenance and Service.

Revision B Page 1-3
1.1.6 SOFTWARE OVERVIEW

Microsoft Windows® XP Professional® is preinstalled as the operating system for the
embedded Pentium III computer, which provides a graphics interface between the
operator and the JFTOT III control program. The JFTOT III software automatically
performs the user-selected operations while displaying the results graphically and
digitally on the LCD touch screen. Audible voice outputs from customized .wav files
are also given at various stages during the test and calibration procedures. Driver
software is preinstalled for running associated hardware.
NOTE: The standard MS Windows® XP Professional® screens displayed should be

intuitive to users familiar with the MS Windows environment. For
instructions on using the standard Windows functions available on the
embedded computer, obtain a copy of the MS Windows® XP Professional®
reference book from a local book seller or through the internet.
The JFTOT III software provides a main screen made up of the following major
sections:
• Mode Selection (left)
• Graphics Display and Message Area (center)
• Digital Displays (right)
Submenus allow the user to perform and monitor the functions for the
selected mode.
Since the embedded computer runs MS Windows® XP Professional OS® software it is
capable of operating any additional MS Windows® XP Professional® programs
available for standard PCs. A 40-GB hard drive provides storage for system programs
and data.
NOTE: A watchdog timer is used by JFTOT III to monitor program activity. If for
some reason the PC locks up or the program simply stops running, the
watchdog timer will remove power from the hardware and completely vent
the pressure from the system.

Page 1-4 Revision B
1.1.7 JFTOT III SIMPLIFIED BLOCK DIAGRAM

The following block diagram shows the basic operational elements for the JFTOT III
analyzer.
FIGURE 1-2
JFTOT III SIMPLIFIED BLOCK DIAGRAM
Touch Screen LCD
Microsoft Windows XP Professional OS

PC Hardware
JFTOT III Application Software
Data Acquisition PCB (DAQ)
Sample Sample Sample Sample

Bus-Bar
Tube Coolant Pressure Flow Aeration
Heat Control Control Control
Control
Control
Deposit Collection Tube Sample Delivery System

Revision B Page 1-5
1.2 FUNCTIONAL OVERVIEW

Major subassemblies and their functional relationships for the JFTOT III are shown
in the following block diagram. See flow diagrams in the back of this manual for
alternate sample flow conditions.
FIGURE 1-3
JFTOT III FUNCTIONAL BLOCK DIAGRAM (NORMAL OPERATION)
User I/O 115VAC 115VAC To

115VAC Fans (x2)
DAQ 24-VDC
Computer/JFTOT III Interface PCB
Touch Screen, Signals 24-VDC Supply Power Distribution
Computer and PCB
Bus Relay Cont
DAQ Assemblies
24 VDC Sample DP Sol Cont Bar Tube RMS RMS
OUT Temp In Out (x5) Temp Temp Volts Amps From Syst
Pres Xdcr 115 115/230
RS-232 Com 4-20 VAC
VAC
& En ma
To To Air
Pump To Step-Down
To Sample % RH To Purge
To Samp SCR Heater Control Transformer
Drive Pump Sensor and Vent
Coolant Drive (230/115VAC)
Solenoids
Pump Pump
Sol Cont
+ Purge 115 or
+ 230 VAC Power Entry
Sol
Module
Valve
Diff Bypass
Pressure Sol Flow Coolant
Xducer Valve Meter Container
Sol Cont
– Purge
Sol – DP
Valve Filter
Back
Pressure 24VDC From Cooling Check
Regulator Computer Pump Valve
System Syst Interface PCB
Vent Sol Press
Sol Cont Valve Xdcr
To Comp
IF PCB
Safety
Sol Cont Vent Sol Radiator
Valve Pre-
Assembly
Filter
Radiator
Fan
Sample and Purge Sample Com & Enable 115VAC
OUT Container Sample-IN Container Drive To Computer To Fans from
Pump Interface PCB Power Dist PCB
% RH Flow
Air Pump Dryer Vent Fan
Sensor Meter
RS-232 To
Computer
24VDC From Comp IF PCB

Comp IF PCB
Aerated Sample Coolant Air

Page 1-6 Revision B
1.3 THEORY OF OPERATION

The fuel sample is placed in a sample container, aerated, and any air in the
The fuel sample is placed in a sample container, aerated, and any air in the test
section purged. The fuel system is then pressurized to 500psig and the temperature of
the specially machined and polished heater tube increased to the programmed
setpoint. A motor-driven isocratic-type pump forces the fuel through a pre-filter, past
the heater tube, and through a precision differential pressure filter (at a flowrate of
3.0 mL/min for ASTM D 3241). The spent fuel flows into a second container.
The amount of deposits which adhere to the tube and the degree of plugging of the
differential pressure filter are indicative of the thermal stability of the fuel at the test
temperature. After the prescribed test period (150 minutes for ASTM D 3241) the
maximum pressure drop across the filter is measured and recorded. The heater tube
is inspected to determine the tube rating. Both the tube rating and the pressure drop
data are typically part of the specification for jet fuel.

Revision B Page 1-7
1.4 COMPONENT DESCRIPTIONS

Components of the JFTOT III are described in the following subsections.
1.4.1 FRONT PANEL

The JFTOT III front panel is divided into the four areas listed below and depicted in
Figure 1-4.
• Touch Screen Area
• Sample Container Area
• Sample Test Area
• Drive Pump Area
FIGURE 1-4
JFTOT III FRONT PANEL USER INTERFACE
Touch Screen
User Interface
Sample Test Area
Sample Container
Area
Drive Pump
Enclosure
1.4.1.1 Sample Container Area

Before a test can be started, a sample-in container and a sample-out
container must be prepared and placed in the proper positions. The
sample-in container is placed at the far left under the sample inlet and
aeration tubes. The sample-out container is placed at the right of the
sample-in container under the sample out and vent out lines as shown
in Figure 1-5.
The aeration tube, inlet tube and a temperature probe are inserted in
the sample-in container along with the fuel sample. Sample and vent
outlet lines are located above the sample out container. Transparent
covers enclose the sample test area to keep the sample confined to the
vented enclosure.

Page 1-8 Revision B
FIGURE 1-5
JFTOT III SAMPLE CONTAINER AREA
Aeration Tube Sample Out Line
Sample-In Tube Vent Out Line
Sample-In
Thermocouple
Sample Out
Sample-In
Container
Container
1.4.1.2 Heater Tube Test Area

Before each test is started, a new heater tube and DP filter must be
installed in the heater tube test section. A new pre-filter element must
be installed in the pre-filter assembly before each test.
The heater tube test section is installed between the bus bars as shown
in Figure 1-6. Lines must also be installed and connections made as
described in Section 3.4.3 “Test Section Installation Procedures”.
Rotometer type flow meters located at the top of the test area are used
to monitor and set the flow rate for the aeration air and coolant. A
thermocouple is placed at the point of maximum temperature inside the
heater tube.
A transparent cover encloses the sample test area to keep the sample
confined to the vented enclosure and prevent drafts from affecting the
test results.
FIGURE 1-6
JFTOT III HEATER TUBE TEST AREA
Heater Tube
Bus-Bar
Thermocouple
Thermocouple
Air Flowmeter Coolant Flowmeter
Upper Bus Bar
– DP Port (Out)
DP Filter
Heater Tube + DP Port (Out)

Test Section
Lower Bus Bar

Pre-Filter
Assembly

Revision B Page 1-9
1.4.1.3 Drive Pump

The drive pump enclosure houses the sample pump behind a removable
panel. The drive pump (Figure 1-7) is used to move the fuel under
pressure (500psi) through the sample delivery system at a constant
flow rate.
Refer to the Model 1500 Dual Piston Pump Operator’s Manual supplied
with the JFTOT III for detailed descriptions, operation and
maintenance information.
FIGURE 1-7
JFTOT III DRIVE PUMP
Purge/Priming
Valve and Port
Reciprocating
Displacement Piston
Pump Heads
Anti-Siphon
Check valve
Input Line
Fittings
Output Line Fitting
1.4.1.4 Main Screen Display

The operator is able to input and receive information concerning the
JFTOT III operations via the front panel computer touch screen as
shown in Figure 1-8. A stylus or the operator’s finger tip can be used to
choose options or input values directly on the touchscreen. A keyboard
and mouse are also provided for use as input devices.
Upon completion of power up, the main screen is displayed as shown in
Figure 1-8
FIGURE 1-8
MAIN SCREEN DISPLAY (EXAMPLE)

Page 1-10 Revision B
The left side of the screen contains five mode buttons that allow the
user to enter the Run Default Test mode, Run Custom Test mode,
Maintenance (Manual) mode, Auto-calibration mode or Report mode.
The center section displays a real-time chart of bus-bar temperature,
watts dissipated and heater tube temperature and a differential
pressure chart for the test operation in progress or stored data from
previous tests.
A display section at the bottom of the center section gives messages
pertaining to the status of the operation in progress. The right section
of the display provides digital readouts for parameters measured during
the test.
After the test is complete, the main screen is displayed with the
temperatures charted as shown in Figure 1-9.
Refer to Appendix 3-A and 3-B in Section 3 for more information on
the JFTOT III program and detailed descriptions of the main screen
and subordinate screens.
FIGURE 1-9
FRONT PANEL TOUCH TEST COMPLETE SCREEN DISPLAY (EXAMPLE)
1.4.2 BACK PANEL

The JFTOT-III back panel has the following components listed below and depicted in
Figure 1-10.
• Ventilation Fans
• Fuses
• Connectors (LAN, Keyboard, Mouse and Printer)
• Dryer
• Power Entry Module

Revision B Page 1-11
FIGURE 1-10
BACK PANEL COMPONENTS
Vent Fan
Fuses (x5)
Dryer
Coolant Power Entry

Radiator Fan Module
Connectors

JFTOT 230
MARK III
USER’S MANUAL
SECTION 2: INSTALLATION
PN: AL-59322
Revision B


05.18.06
REVISION HISTORY
ALCOR JFTOT III Users Manual Section 2: Installation
Section 2: TABLE OF CONTENTS

SECTION 2: INSTALLATION .................................................................................................1
2.1 INSTALLATION REQUIREMENTS .............................................................................1

2.1.1 Environmental and Space Requirements............................................................................... 1
2.1.2 Electrical Requirements .......................................................................................................... 2
2.2 INSTALLATION PROCEDURES..................................................................................3
2.2.1 Unpacking and Inspection ...................................................................................................... 3
2.2.2 Power Entry Module Fuse Configuration.............................................................................. 5
2.2.3 Aeration Dryer Assembly Installation ................................................................................... 5
2.2.4 Bus-Bar Thermocouple and Clamp Installation..................................................................... 6
2.2.5 Vent Line Installation.............................................................................................................. 7
2.2.6 Final Installation Steps............................................................................................................ 7
Appendix 2-A: SHIPPING DAMAGE REPORTS ...............................................................1
Appendix 2-B: INSTALLATION PROBLEM REPORT ......................................................1

SECTION 2:
INSTALLATION
2.1 INSTALLATION REQUIREMENTS
Prior to installing the JFTOT 230 Mark III Jet Fuel Thermal Oxidation Tester
(JFTOT III), environmental and operational requirements must be considered in
order to ensure proper installation and future performance. The following
requirements must be considered before installing the JFTOT III.
2.1.1 ENVIRONMENTAL AND SPACE REQUIREMENTS

• Environmental Requirements: Non-hazardous, non-corrosive, dust-free
operating environment with reasonable ventilation associated with a “typical”
modern laboratory environment is normally acceptable.
• Room Temperature:+10°C to +35°C
• Relative Humidity: 20% to 90% non-condensing
• JFTOT III Location and Space Requirements: A typical lab bench or table
strong enough to support at least 100 kg and having surface area and height
above the surface as listed below:
• Width: 22 inches (56 cm)
• Depth: 24 inches (59cm)
• Height above surface: 30 inches (76cm)
NOTE: Allow space in front of the JFTOT III to open the sample pump enclosure
door and to open the sample containers and test area covers.
NOTE: Allow space in back of the JFTOT III to remove the Dri-Rite container, to
access the power entry module and to connect power and signal cables.
NOTE: Allow space on each side of the JFTOT III to remove the side panels and
access the internal components.
CAUTION: Fan exhaust from the JFTOT III may affect other instruments and surfaces in
back of the JFTOT III.
• Printer Location and Space Requirements: Ideally, the user-supplied color

printer (with USB interface) should be placed to the right or left of the JFTOT
III. This requires additional bench space equal to the footprint of the printer
selected. The printer may be placed on top of the JFTOT III if bench space is
not available.

Revision B Page 2-1
• Keyboard and Mouse Location and Space Requirements: The keyboard

and mouse can be placed on top of the sample and heater tube area covers
when closed. If the keyboard and mouse supplied with the JFTOT III are
placed directly in front of the JFTOT III additional bench space is required as
listed below.
• Width: 12 inches
• Depth: 6 inches
CAUTION: Do not allow fuel or cleaning fluids to spill onto the keyboard or mouse.
2.1.2 ELECTRICAL REQUIREMENTS

• JFTOT III Electrical Requirements: A breaker-protected 115 VAC or 230
VAC, standard single-phase wall outlet capable of delivering power required
to operate the JFTOT III as listed below:
• Operating Power Voltage: 115VAC or 230VAC (±10%) single phase
• Operating Power Frequency: 50Hz or 60Hz (±5%)
• Fuse ratings: 8A at 115VAC, 6.3A SB at 230VAC

Page 2-2 Revision B
2.2 INSTALLATION PROCEDURES

CAUTION: Only trained personnel with prior knowledge of all pertinent safety
procedures and operations are allowed to install, operate and service the
JFTOT III.
After determining the location for the JFTOT III as required in Section 2.1, unpack
and install the JFTOT III by performing the following procedures.
2.2.1 UNPACKING AND INSPECTION

1. Carefully, unpack each item as listed in the packing list and inspect for damage.
2. Check each of the items shown in Figures 2-1A-21D and note any damaged or
missing items.
NOTE: See Appendix 2-A at the end of this section to report damages due to
shipping.
NOTE: Included are enough consumables to perform 20 tests.
FIGURE 2-1A
JFTOT STANDARD ACCESSORIES AND LINES
Test Section Cover

Sample Vessels Cover
Fuel Sample In and

Out Containers
(68019)
Sample Vessels Tray

Test Section Tray
(AL-08214)
(AL-08217)
Aeration and Fuel
Sample-In Tubes
Sample and Vent
Lead Auto-Cal Heater Assy
Output Lines
(AL-35387)
Bus-Bar TC
Hold-Down Clamp Heater Tube TC (AL-86303
Test Section Outlet Line
Bus-Bar TC (AL-86302)
Test Section (AL-35291)
Sample Fuel TC (AL-86301)
Fuel Sample Input Line
Pre-Filter Assembly
(AL-27075)
NOTE: See Section 5.8 for a listing of spares, accessories, supplies, and materials.

Revision B Page 2-3
FIGURE 2-1B AND C

JFTOT SOFTWARE POWER CORD, KEYBOARD AND MOUSE
B C
Power Cord
MS Windows XP
Professional OS
Software
Keyboard
Driver Software
Mouse
JFTOT III Software
FIGURE 2-1 D
JFTOT III SPARES, ACCESSORIES, SUPPLIES AND MATERIAL
Kim Wipe Wash Bottles (x2)

Towels (p/n AL-38013)
(p/n AL-89034)
Cleaning Tray Gloves, Disposable
(x1) (AL-38012) (p/n AL-38033)
Aluminum Foil
(AL-38008)
Heater Tube Heater Tubes (2
Insulators packs of 10)
(2 packs of 4) (p/n AL-91652)
(AL-11926)
Packaged Items Standardization Kit
(Figure 2-1E) (AL-37633)
FIGURE 2-1 E
JFTOT III PACKAGED SPARES, ACCESSORIES, SUPPLIES AND MATERIAL
Silicone Grease (AL-38018)
Filter Papers (AL-27052)

Squeeze Bulb
(AL-38010) Pre-Filter Kit
(Box of 25 elements)
(AL-38057)
Hex Driver
(AL-38016) O-Rings (Pack of 25)
(AL-53706)
Brush (AL-09970)
Insulator Bushing Fuses 1.5 A (x5)

Extraction Tool (AL-29737)
(AL-38017)
Fuses 0.75 A (x5)
Fuses 0.5 A (x5) (289034)
(289036)
Fuses 2 A PCB (x10)
(AL-29735)
Fuses 8 A (x5) for Fuses 4 A (x10) (AL-29736)

115VAC (AL-29686)
Tweezers (x1) Fuses 6.3 A 5x20mm (x10)

(AL-38009) (AL-29738)

Page 2-4 Revision B
3. Inspect the exterior of the JFTOT III for damage.

4. Remove the side panels from the JFTOT III. Inspect all components and
connectors for damage, tightness and leakage.
5. Check the coolant reservoir for leaks and proper fluid level. The container
should be approximately half full.
6. Lift the JFTOT III onto the predetermined lab bench or table.
WARNING: Physical injury and equipment damage may occur unless at least 3 people
capable of lifting at least 100 pounds each are used to lift the JFTOT III into
place.
2.2.2 POWER ENTRY MODULE FUSE CONFIGURATION

Check the power entry module for correct 115/230VAC orientation
as required for the available power receptacles. Either 115 or 230 should show in the
module window. If not oriented correctly, refer to Section 5.4.5 in Maintenance and
Service.
NOTE: For 115 VAC use one 8A-3AG, Fast (PN: AL-29686) and a shorting clip.
For 230 VAC use two 6.3A, 5x20mm Slow-Blow (PN: AL-29738) without the
shorting clip. If metal shorting clip is not available, install an 8A Fuse in both
sides of the holder.
2.2.3 AERATION DRYER ASSEMBLY INSTALLATION

If not installed, perform the following steps to install the dryer assembly for the
aeration system used in JFTOT III. See Section 5.2.2 “Maintenance” for Dri-Rite
chemical replacement procedure.
1. Locate the dryer assembly spring-clip mounting brackets at the back of the
JFTOT on the right-hand side.
2. Orient the dryer assembly so that top fittings align and press the dryer into the
clip mounts as sown in Figure 2-10.

Revision B Page 2-5
FIGURE 2-10
AERATION DRYER INSTALLATION
Top Fittings
Clip Mounts
Dri-Rite
Dryer Assembly
Chemicals
(Blue)
Barbed Fitting
3. Thread the top fitting onto the top of the dryer assembly fitting and press the
bottom line over the bottom tapered fitting. Tighten the air- in and air-out
fittings to finger tight.
4. If necessary, loosen the top end cap and rotate the window so that it can be
viewed from the side of the JFTOT. Retighten the end cap.
5. Test the aeration system for leaks.
6. Check color of blue Dri-Rite chemicals. Pink indicates Dri-Rite chemicals need
to be replaced.
2.2.4 BUS-BAR THERMOCOUPLE AND CLAMP INSTALLATION

1. If not installed, insert the bus-bar thermocouple connector (Figure 2-11) into the
bus-bar thermocouple bulkhead connector.
FIGURE 2-11
JFTOT III BUS-BAR TC AND CLAMP INSTALLATION
Bus-Bar
Thermocouple
Connection
Heater Tube
Clamp Assembly
Upper Bus-Bar
Thermocouple Assembly
Wire Insertion
Thermocouple Hold-
Down Clamp Set Screw
Stop Adjustment
Thermocouple Hold-
Screw
Down Clamp

Page 2-6 Revision B
2. Insert the thermocouple wire into the orifice (Figure 2-11) near the end cap of
the upper bus bar.
3. With the thermocouple hold-down clamp set screw to the right and the flat
section of the clamp at the bottom, align thermocouple slot with the
thermocouple wire and slide the thermocouple hold-down clamp over the
thermocouple wire and onto the upper bus bar (Figure 2-11) until it stops. If
necessary, adjust the stop screw on the flat section of the clamp.
4. Tighten the set screw to hold the thermocouple hold-down clamp in place.
5. Install the heater-tube clamp assembly (Figure 2-11) onto the thermocouple hold-
down clamp using the two hex screws.
2.2.5 VENT LINE INSTALLATION

1. Ensure the o-ring is in place on the end of the vent line.
2. Insert the metal vent lines (Figure 2-12) into the front panel bulkhead fittings as
shown in Figure 2-12.
3. While keeping the end of the line aligned, finger-tighten the knurled nut
(Figure 2-12) onto the bulkhead fittings.
FIGURE 2-12
SAMPLE AND VENT OUTPUT TUBES
O-Ring
Nut
2.2.6 FINAL INSTALLATION STEPS

1. Reinstall the side panels.
2. Install the trays in the floor of the sample vessel area and the test section.
3. Install the covers over the sample vessel area and test section by sliding the cover
hinges into the hinge receptacles on the JFTOT.
4. Connect the power cord from the power entry module in the back panel to a
standard wall outlet. Ensure the wall outlet voltage is the same voltage as
indicated in the power entry module window.
5. Place the printer, keyboard and mouse in the predetermined locations near the
JFTOT III and connect the keyboard, mouse and printer cables to the back panel
connections shown in Figure 2-13.
Revision B Page 2-7
FIGURE 2-13
JFTOT III POWER, KEYBOARD, MOUSE AND PRINTER CABLES I
6. Connect the USB printer cable to the printer.

7. Connect the printer power cord from the back of the printer to a convenient
power outlet.
8. If a network connection is required, plug the network cable into the LAN
connection on the JFTOT III back panel.
The basic installation procedures are now complete as shown in Figure 2-14. The
JFTOT III should now be ready for the initial startup as described in Section 3.1.
FIGURE 2-14
JFTOT III COMPLETED INSTALLATION

Page 2-8 Revision B
ALCOR JFTOT III Users Manual Appendix 2-A: Shipping Damage Reports
APPENDIX 2-A:
SHIPPING DAMAGE REPORTS
Shipments are inspected immediately prior to being packaged for transportation. Since
our packaging exceeds all freight specifications, your equipment should have arrived
in perfect condition.
Our terms of sale are through Ex Works at shipping point, meaning that title to these
goods is passed to the final receiver when the goods were transferred to the carrier at
our factory. If any part of the shipment is damaged, we suggest reporting the damage
immediately to the transportation company. The following procedure for reporting
damaged equipment is suggested.
CAUTION: Before shipping the JFTOT III or accessories, flush all sample fuel from the
lines and clean all glass containers.
Common Carrier:
If the item is discovered at the time of delivery, have the driver note the nature and
extent of the damage on the carriers copy and on the delivery copy of the freight bill.
If the item is discovered after delivery, call the carrier immediately after discovering
the damage, and request that an inspection be made as soon as possible. Perform the
following steps when damage items are found after delivery.
1. Contact the carrier immediately for an inspection of the item(s).
NOTE: It is essential that the damaged item(s) be left in the original shipping
container(s).
2. Obtain a copy of the inspection report to support your claim.
NOTE: Claims on air shipments must be filed within 270 days. Other claims must be
filed within 9 months of the shipping date.
3. File the claim as quickly as possible, even if you have to estimate the dollar
amount of the damage.
Parcel Delivery Service (UPS, DHL, FEDEX, etc):
NOTE: All claims must be initiated by the receiver.
Follow the steps listed above for reporting damages shipped by common carriers, and
notify our office in Houston, Texas by dialing 281-5800-339. Our Technical Service
Department will help you process your claim.
NOTE: Do not return the system or any item to the factory without factory
authorization.
Revision B Page 2A-1
ALCOR JFTOT III Users Manual Appendix 2-A: Shipping Damage Reports
United Parcel Service (UPS):
NOTE: All claims with UPS must be initiated by the receiver.
Unless otherwise specified, UPS is the preferred primary carrier for ALCOR
shipments. Follow the steps listed above for reporting damages shipped by common
carriers, and notify our Customer Service Department, which will take the necessary
action for your claim.
NOTE: Do not return the system or any item to the factory without factory
authorization.
CAUTION: Before shipping the JFTOT III or accessories, flush all sample fuel from the
lines and clean all glass containers.

Page 2A-2 Revision B
ALCOR JFTOT III Users Manual Appendix 2-B: Installation Problem Report
APPENDIX 2-B:
INSTALLATION PROBLEM REPORT
Complete the following report if there are any problems with the installation of the
JFTOT III and send it by email attachment to the PAC Service Department.

Revision B Page 2B-1
ALCOR JFTOT III Users Manual Appendix 2-B: Installation Problem Report

Page 2B-2 Revision B
Installation Problem Report
Company: Installation Date:

Contact: Installed By:
Address: PAC Representative:
Sales Order #:
City: St: Zip:
Country: Territory: Fax or e-mail complete report to Service Manager
Phone: Fax: fax: 281-580-0719 e-mail: service@paclp.com
E-mail:
Purchase Date S/N Model # Install Date
Problem(s)
Model: S/N:
Part # Description of Problem
Model: S/N:
Model: S/N:
Type of Problem: Appearance Broken Electronic Missing Off Spec Wrong

Assembly Electric Leak Mechanical Non-function
JFTOT 230
MARK III
USER’S MANUAL
SECTION 3: OPERATION
PN: AL-59322
Revision B


03.18.06
REVISION HISTORY
SECTION 3: OPERATION ...................................................................................................... 1
3.1 INITIAL STARTUP PROCEDURES ............................................................................ 1
3.1.1 Help Screen .............................................................................................................................2
3.1.2 Preparation .............................................................................................................................2
3.2 RUNNING A DEFAULT TEST..................................................................................... 3
3.3 CLEANING.................................................................................................................... 4
3.4 ASSEMBLY ................................................................................................................... 8
3.4.1 Pre-Filter Assembly and Installation.....................................................................................8
3.4.2 Heater Tube Test Section Assembly Procedures .................................................................9
3.4.3 Test Section Installation Procedures.................................................................................. 12
3.4.4 Preparation of Test Fuel ..................................................................................................... 14
3.5 DISASSEMBLY ........................................................................................................... 16
3.6 SHUTDOWN ............................................................................................................... 20
APPENDIX 3-A: JFTOT III SCREEN DESCRIPTIONS........................................................ 1

3-A.1 JFTOT III MENU STRUCTURE................................................................................... 1
3-A.2 JFTOT III MAIN SCREEN DESCRIPTION ................................................................. 2
3-A.2.1 Main Screen Top Section ...................................................................................................2
3-A.2.1.1 JFTOT III Version ......................................................................................................2
3-A.2.1.2 Machine Number ........................................................................................................3
3-A.2.1.3 Measure .......................................................................................................................3
3-A.2.1.4 Date and Time.............................................................................................................3
3-A.2.1.5 Test ..............................................................................................................................3
3-A.2.2 Main Screen Left Panel ......................................................................................................3
3-A.2.2.1 Auto-Cal Date..............................................................................................................3
3-A.2.2.2 Run Default Button ....................................................................................................3
3-A.2.2.3 Run Custom Test ........................................................................................................4
3-A.2.2.4 Maintenance................................................................................................................4
3-A.2.2.5 Auto Calibration .........................................................................................................4
3-A.2.2.6 Reports ........................................................................................................................4
3-A.2.2.7 Exit Program ...............................................................................................................4
3-A.2.3 Main Screen Right Panel....................................................................................................4
3-A.2.3.1 Flow mLpm .................................................................................................................5
3-A.2.3.2 Test Setpoint ...............................................................................................................5
3-A.2.3.3 Heater Tube Temp......................................................................................................5
3-A.2.3.4 Bus-Bar Temp..............................................................................................................5
3-A.2.3.5 Inlet Temp ...................................................................................................................5
3-A.2.3.6 Sys Pres........................................................................................................................5
3-A.2.3.7 Diff Pres.......................................................................................................................6
3-A.2.3.8 Watts............................................................................................................................6
3-A.2.3.9 Tube Resistance ..........................................................................................................6
3-A.2.3.10 % power ......................................................................................................................6
3-A.2.4 Graphics and Message Panels ............................................................................................7
3-A.2.4.1 Temperature Chart .....................................................................................................7
3-A.2.4.2 Differential Pressure Chart ........................................................................................7
3-A.2.4.3 Chart Controls.............................................................................................................7
3-A.2.4.4 Message Display..........................................................................................................9
3-A.2.5 Help .....................................................................................................................................9
APPENDIX 3-B: JFTOT III OPERATION DETAILS............................................................ 1
3-B.1 Overview....................................................................................................................... 1
3-B.1.1 Run D3241 Test (Default Test) ........................................................................................1
3-B.1.2 Reports ................................................................................................................................5
3-B.1.2.1 Traditional Report ......................................................................................................6
3-B.1.2.2 Custom Report ............................................................................................................7
3-B.1.3 Test Setup Parameters........................................................................................................8
3-B.1.4 Run A Custom Test......................................................................................................... 10
3-B.1.5 Maintenance .................................................................................................................... 16
3-B.1.5.1 Aeration.................................................................................................................... 18
3-B.1.5.2 Drive Pump .............................................................................................................. 19
3-B.1.5.3 Sys Vent.................................................................................................................... 20
3-B.1.5.4 DP+ Vent and DP – Vent....................................................................................... 20
3-B.1.5.5 DP Bypass................................................................................................................. 21
3-B.1.5.6 Bus Heater ................................................................................................................ 21
APPENDIX 3-C: HEATER TUBE DEPOSIT RATING ......................................................... 1

3-C.1 Visual Tuberater Operation.......................................................................................... 1
3-C.2 Video Tube-Deposit Rater Operation ........................................................................... 4
APPENDIX 3-D: PRECAUTIONARY STATEMENTS FOR HAZARDOUS MATERIALS . 1

ALCOR JFTOT III Users Manual Section 3: Operation
SECTION 3:
OPERATION
3.1 INITIAL STARTUP PROCEDURES
After completing the basic installation procedures for the JFTOT 230 Mark III Jet
Fuel Thermal Oxidation Tester (JFTOT III), the JFTOT III can be setup to run a
test. The JFTOT III has been thoroughly tested by PAC before delivery. The factory
tests are stored in files on the JFTOT III hard drive for evaluation and comparison to
tests performed after installation.
NOTE: Become familiar with the location and use of all controls, indicators,
connections, and accessories. Carefully read all instructions, warnings
cautions and labels prior to operating any portion of the system. Failure to
do so could result in personal injury and equipment damage.
Perform the following steps to startup the newly installed JFTOT III.
1. Locate the JFTOT III power-on/off switch on the back panel in the power entry
module and place the switch in the ON position. Ensure the power switch in
back of the computer near the power cord is always in the ON (–) position.
2. Press the computer power switch on the front panel (lower-left of computer).
The JFTOT III should power up through the normal Windows power up
routine. The JFTOT III program is automatically loaded from the Windows OS
and will display the JFTOT III main screen after the loading process has
completed. The main menu screen shown in Figure 3-1 should appear.
FIGURE 3-1
JFTOT III MAIN MENU SCREEN (EXAMPLE)
The JFTOT III is now ready to setup to run tests.

Revision B Page 3-1
NOTE: To start the JFTOT III program from the Windows desktop, touch or click
the JFTOT III icon on the Windows Desktop or click
Start>Programs>JFTOT III. To return to the Windows desktop from the
JFTOT III main menu, click or press the EXIT button on the main menu.
NOTE: Refer to Appendix 3-A in this section of the user’s manual for detailed
descriptions of the structure and screens displayed by the JFTOT III
application program and Appendix 3-B for a detailed description of the
JFTOT III operations and how to setup DEFAULT test parameters.
3.1.1 HELP SCREEN

HELP information is available for all screen areas and controls by pressing the
CTL and H keys at the same time and then positioning the cursor over the screen
area or control in question. An information box appears (Figure 3-2) with an
explanation of the control function. Pressing the CTL and H keys again clears the
HELP function and returns the JFTOT III to normal operation.
FIGURE 3-2
JFTOT III MAIN SCREEN – HELP (EXAMPLE)
3.1.2 PREPARATION
Before you can begin a JFTOT test as described in Subsection 3.2, the components
exposed to jet fuel musts be cleaned and reassembled as described in Sections 3.3 and
3.4. The following replacement components must be obtained for each test:
• Pre-filter element (AL-238057 - box of 25)
• Heater tube and filter kit (AL-91652 - box of 10)
• General-purpose, retentive, qualitative filter paper (AL-27052 - box of 100)

Page 3-2 Revision B
3.2 RUNNING A DEFAULT TEST

The steps in running a Default test are provided in the following Quick-Start Guide.
Refer to Sections 3.3 and 3.4 to complete Step 1. Refer to Appendix 3-C for heater
tube deposit rating and to Section 3.6 for shutdown instructions.
1. Press or click the RUN DEFAULT button on the main screen (right). The
Test Annotation screen (below left) appears.
2. Fill in the blanks and then click OK. An instruction box (below right) will
appear prompting you to perform setup.
3. Refer to Section 3.3 and 3.4 in the User’s Manual for detailed setup
procedures.
4. After completing the setup steps, press or click the CONTINUE button.
The system will automatically begin the 6-minute preparation process

and display the progress pane l (right). The progress panel requires no
user input unless it is necessary to skip the preparation process or abort
the test.
5. Adjust air and coolant flowmeters so that the ball is in the center of the
green range.
After the preparation process is complete, the test-in-progress screen

appears and the green “Test Running” indicator lamp (right) is lit to
confirm the test is running.
6. When the option box (below) appears, press or click YES to save the file
or NO if the data is to be deleted.
7. If YES is selected, the Traditional Report Form (right) will be displayed.
8. Fill in any missing information on the traditional form.
9. Touch or click the OK button. The report will automatically be printed.
10. Perform disassembly and cleanup steps. Refer to Section 3.5 in the
User’s Manual for detailed disassembly and cleanup procedures.
11. Refer to Appendix 3-C in the User’s Manual for instructions on heater tube
deposit rating.

Revision B Page 3-3
3.3 CLEANING
WARNING: These procedures involve handling flammable liquids and exposure to skin
irritants and harmful vapors. Wear protective clothing, gloves and mask
when setting up and performing the JFTOT III tests. Ensure flames and
spark producing materials are kept well away from the JFTOT III test area.
Use standard safety procedures at all times.
Before you can setup to run a JFTOT test, all components containing test fuel must
be clean and free of contaminants. Perform the following steps to clean the
components.
1. Place a new piece of aluminum foil about 450 mm square or larger on the bench
for placing all components after cleaning.
2. Position a cleaning pan to catch the solvent during the cleaning operations.
3. Use a wash bottle filled with solvent to flush most components.
WARNING: There are three appropriate solvents for general cleaning: cyclohexane, n-
heptane, and 2,2,4 trimethyl pentane (isooctane). These solvents are
extremely flammable and the vapors are harmful. Wear protective clothing,
gloves and mask when using these solvents. Ensure flames and spark
producing materials are kept well away from the area. See Appendix 3-D.
4. Flush the pre-filter components with solvent as shown in Figure 3-3A through
3-3C and thoroughly blow dry line using a squeeze bulb as shown in
Figure 3-3D.
FIGURE 3-3
PRE-FILTER COMPONENTS FLUSHING
A B C D
5. Flush the fuel sample inlet line with solvent as shown in Figure 3-4A and
thoroughly blow dry using a squeeze bulb.

Page 3-4 Revision B
6. Flush the fuel sample inlet line and the test section outlet line with solvent as
shown in Figure 3-4 and thoroughly blow dry using a squeeze bulb.
FIGURE 3-4
FUEL-INLET LINE AND TEST SECTION OUTLET LINE FLUSHING
A B
Test Section
Outlet Line
Solvent
Fuel Sample (N-Heptane)
Inlet Line
7. Flush the sample-in thermocouple, sample-in line and the aeration line with
solvent.
8. Flush all inside surfaces of the fuel sample-in container and sample-out
container with solvent as shown in Figure 3-5.
FIGURE 3-5
FUEL-IN CONTAINER FLUSHING
Fuel Sample-In Solvent

Container (N-Heptane)
WARNING: Trisolvent is a blend of equal amounts of acetone, toluene and isopropanol.

It is extremely flammable and the vapors are harmful. Wear protective
clothing, gloves and mask when using this solvent. Ensure flames and spark
producing materials are kept well away from the area. See Appendix 3-D.
9. Using the stiff nylon brush (supplied) saturated with trisolvent, brush the inside
surfaces of the test section while flushing with trisolvent as shown in Figure 3-
6. This is the only component that requires cleaning with trisolvent.
10. Visually inspect the inner surfaces of the test section cleanliness and repeat
cleaning with trisolvent as required to remove all deposits.

Revision B Page 3-5
FIGURE 3-6
HEATER TEST SECTION FLUSHING
Stiff Nylon
Brush
Heater Tube
Housing
Solvent
(Tri-Solvent)
11. Flush the test section and its bypass line with solvent and blow dry with a
squeeze bulb as shown in Figure 3-7.
FIGURE 3-7
SQUEEZE-BULB DRYING
Test Section
Squeeze Bulb
12. Flush the insulator bushings and test section nuts with solvent.
13. Inspect all o-rings for cuts, abrasions, and excessive swelling and replace as
necessary. Inspect the insulators and replace if they are cracked, chipped, or
otherwise damaged. Inspect all stainless steel components for damage and
replace as necessary.
14. The cleaned parts are now ready for assembly (Figure 3-8).

Page 3-6 Revision B
FIGURE 3-8
CLEANED COMPONENTS
Sample Containers (x2)
Test Section Nuts

Insulator Bushings
Test Section
Pre-Filter In Housing
Bypass Line
Pre-Filter O-Ring
Test Section
Outlet Line
Pre-Filter Backup Screen
Pre-Filter Out Fuel Sample-In
Housing Line

Revision B Page 3-7
3.4 ASSEMBLY
3.4.1 PRE-FILTER ASSEMBLY AND INSTALLATION
Perform the following steps to install a new pre-filter element in the pre-filter assembly.
NOTE: For each test, a new 25 mm diameter, 0.45 µm membrane filter element
(white in color) must be installed along with a clean backup screen, o-ring
and housing sections as shown in Figure 3-9.
FIGURE 3-9
JFTOT III PRE-FILTER ASSEMBLY
Pre-Filter Housing
Pre-Filter Housing Screws (x3)
Bottom Plate and
Inlet Line
Pre-Filter O-Ring
Pre-Filter Element
25 per box
(p/n AL-38057)
Pre-Filter Backup
Screen
Pre-Filter Housing
Base Plate
1. Using clean, flat-blade (non-serrated) tweezers, install the filter-element back-

up screen (Figure 3-10A) in the pre-filter housing recess.
2. Using clean, flat-blade (non-serrated) tweezers, place the 0.45 µm white

membrane filter element (Figure 3-10B) on the back-up screen.
3. Install the large o-ring inside other half of the pre-filter housing and the small
o-ring on the tube connection as shown in Figure 3-10C.
FIGURE 3-10
PRE-FILTER ELEMENT INSTALLATION
A B C
Filter Backup Screen
Small O-Ring
Large O-Ring
Filter Element (White)

Page 3-8 Revision B
4. Assemble the two housing sections together (Figure 3-11A) by inserting the
three screws through the lower section and tightening securely.
5. Connect the pre-filter assembly to the fuel-in fitting (Figure 3-11B) and finger-
tighten snugly.
FIGURE 3-11
PRE-FILTER HOUSING ASSEMBLY
A B
Pre-Filter Assembly
Fuel-In Fitting
3.4.2 HEATER TUBE TEST SECTION ASSEMBLY PROCEDURES

A new heater tube and filter kit (p/n AL-91652, box of 10) is required for each test.
The kit consists of a heater tube, test filter, and three o-rings (Figure 3-12). Perform
the following steps to assemble these new items into the test section.
FIGURE 3-12
NEW JFTOT HEATER TUBE NEEDED FOR EACH TEST
DP Filter Heater Tube
O-Rings (x3)
Heater Tube
Container
CAUTION: During assembly wear clean, dry gloves. Handle the heater tube by the ends
only. If the center section of the heater tube is touched, the tube must be
rejected as the deposit forming characteristics on the tube will be adversely
affected.
CAUTION: Do not reuse heater tubes. Tests indicate that magnesium migrates to the
heater tube surface under test conditions. Surface magnesium may reduce
adhesion of deposits to the heater tube surface.

Revision B Page 3-9
CAUTION: Use caution when removing the heater tube from its protective plastic
container. To prevent bending of the tube, hold the plastic container at one
end with two or three fingers and pull the cap off (do not pry).
1. Remove the yellow cap from the end of the plastic heater-tube container and
then remove the DP filter and three o-rings from the cap.
2. Carefully remove the heater tube from the plastic tube container.
3. Inspect the heater tube as follows:
3.1 Use a visual tuberator to inspect the center section (see Appendix 3-C,
Heater Tube Deposit Rating). Reject any heater tube showing scratches,
unpolished area, or other visual defects.
3.2 Examine the heater tube for straightness by rolling the tube on a clean, flat
surface noting any variation in gap between the surface and the heater
tube center section. Reject any bent heater tube.
CAUTION: Do not touch or allow anything to contact the heater tube center section
during the assembly or disassembly of the heater tube test section.
4. Insert the heater tube into the clean test section until it is centered in the
housing as shown in Figure 3-13.
FIGURE 3-13
JFTOT III HEATER TUBE INSTALLATION
Heater Tube
Test Section
Heater Tube Heater Tube
Serial Number
5. Onto each end of the heater tube, sequentially install a tapered insulator (wide
end out), high temperature o-ring, shoulder insulator (large end first), and hex
nut as shown in Figures 3-14A and 3-14B. Lightly finger tighten nut with the
heater tube approximately centered in the housing.

FIGURE 3-14
JFTOT III HEATER TUBE INSTALLATION
A B
Hex Nut
Shoulder Insulator
O-Ring Tapered Insulator

Tapered Insulator O-Ring
Shoulder Insulator
Hex Nut
6. Observe the heater tube through the fuel discharge hole and align the upper
heater-tube shoulder in the center of the discharge hole as shown in
Figure 3-15.
FIGURE 3-15
JFTOT III HEATER TUBE POSITION
Heater Tube
Shoulder
7. While observing the correct heater tube shoulder alignment in the discharge hole,
tighten both hex nuts firmly with fingers only. DO NOT USE A WRENCH.
8. Using clean tweezers, install the DP filter (Figure 3-16A) in the outlet chamber of the
heater tube housing with the RED COLORED SIDE OUT. Place a new o-ring on top
of the DP filter (Figure 3-16B) and press the o-ring in until it rests against the filter
FIGURE 3-16
DP-FILTER INSTALLATION
A B
DP Filter
(Red Side Out) O-Ring

9. Attach the outlet line to the test section as shown in Figure 3-17.
FIGURE 3-17
OUTLET LINE INSTALLATION
3.4.3 TEST SECTION INSTALLATION PROCEDURES

After the heater-tube test section assembly has been completed, it can be installed
into the bus bars in the JFTOT III test area.
1. Before each test, wipe the bus-bar contact areas with a paper tissue that is wet
with solvent. See “Cleaning Bus Bar Contacts” in Maintenance Section 5.2.3.
CAUTION: If the bus-bar caps have been completely removed, check for proper mating.
Matching numbers are stamped on the inside surfaces of the cap and bus
bar. These numbers must match and face each other. To ensure consistent
reassembly, the caps are normally not completely removed from their
respective bus bar.
2. If both screws are in the bus-bar caps, remove one screw and rotate the end
caps to allow installation of the heater tube assembly.
3. Install the new heater tube assembly into the top and bottom bus bars and then
swing the caps into place over the tube and finger tighten the upper and lower
bus-bar screws as shown in Figure 3-18A.
4. Ensure the top of the heater tube is flush with the top of the upper bus bar
(Figure 3-18B) and then use the Allen wrench provided to securely tighten the
upper and lower bus-bar screws as shown in Figure 3-18C.

FIGURE 3-18
JFTOT III HEATER TUBE TEST SECTION INSTALLATION
A B C
5. Attach the test section bypass and outlet lines to the bulkhead fittings as shown
in Figure 3-19. Make sure o-rings are on the ends of the both lines. Tighten
fittings with fingers until snug.
FIGURE 3-19
OUTLET LINE AND BYPASS LINE INSTALLATION
Test Section Outlet

Line Bulkhead
Fitting
Bypass Line Bulkhead

Fitting
6. Ensure an o-ring is in place at both fuel input line fittings and then connect the
fuel input line to the pre-filter fitting and the other end to the fuel-in fitting on
the test section as shown in Figure 3-20. Tighten both fittings with fingers until
snug.

FIGURE 3-20
FUEL INPUT TUBE INSTALLATION
Fuel-Input Fuel-Input Line

Line Test Section Fitting
Fuel-Input
Line Pre-Filter
Fitting
7. If not already installed, plug the heater tube thermocouple connector into the
connector above the bus-bar thermocouple connector as shown in
Figure 3-21A.
8. Carefully, insert the thermocouple tip into the hole at the front of the upper end
of the heater tube (Figure 3-21A) and lower until it stops.
9. Move the thermocouple retaining clip into place around the thermocouple as
shown in Figure 3-21B.
FIGURE 3-21
JFTOT III THERMOCOUPLE INSTALLATION
A B
Heater Tube
Thermocouple
Connector
Thermocouple
Retaining Clip
Heater Tube
Thermocouple
Heater Tube
Thermocouple
Tip
3.4.4 PREPARATION OF TEST FUEL

Perform the following steps to prepare the test fuel.
1. Measure approximately 600 ml of test fuel into a clean graduated container.
2. Place the specified filter paper in a clean funnel and place the funnel into a
clean container.
3. Carefully pour the test fuel into the filter paper and let it drain through the
paper into the container as shown in Figure 3-22.

FIGURE 3-22
TEST FUEL MEASUREMENT
Graduated Cylinder
Filter Paper
(AL-27052, box of 100)
Funnel
Filtered Fuel
Container
4. Pour the filtered fuel into the JFTOT III test sample-in container and place the
container under the aeration and sample-in fittings.
5. Connect the aeration tube and the fuel sample-in tube quick-disconnect fittings
to the appropriate fittings on the JFTOT III front panel as shown in
Figure 3-23.
6. Insert the sample thermocouple into the sample-in container and then plug the
connector to the sample thermocouple connector on the JFTOT III front panel
as shown in Figure 3-23.
FIGURE 3-23
SAMPLE-IN CONTAINER TUBES AND THERMOCOUPLE INSTALLATION
Aeration Quick-
Sample Connect Fitting
Thermocouple
Sample-In Quick-
Connector
Connect Fitting
Aeration Tube
Sample Assembly
Thermocouple Sample-In Tube
(AL-86301) Assembly
Sample-In Container
(68019)
Stone Diffuser
Stone Filter
NOTE: Ensure the fuel temperature is between 15 and 32°C. If necessary, place the
fuel container into a hot or cold water bath as required to bring the fuel
temperature within the limits.

3.5 DISASSEMBLY
After a test has been completed, perform the following steps to disassemble the test
components.
1. Ensure the test section has time to cool.
WARNING: A risk of burns exists unless the test section is cooled prior to disassembly.
2. Remove the sample-in thermocouple, the aeration tube and the sample-in tube
and place them in a clean location.
3. Remove the sample-in and sample-out containers (Figure 3-24) and properly
dispose of fuel.
FIGURE 3-24
SAMPLE-IN AND SAMPLE-OUT CONTAINERS
Aeration and
Sample-In Tube
Fittings
Sample-In
Thermocouple
Sample-In Sample-Out
Container Container
4. Remove the fuel-input line assembly as shown in Figure 3-25.
FIGURE 3-25
FUEL-IN TUBE REMOVAL
Test Section
Fuel Input Fitting
Fuel
Input Tube
Assembly
5. Remove the pre-filter assembly from the front panel fuel-in fitting (Figure 3-26).
Disassemble pre-filter and discard the filter element.

FIGURE 3-26
PRE-FILTER ASSEMBLY REMOVAL
Fuel-In Fitting
6. Disconnect and remove the test section outlet line as shown in Figure 3-27A.
7. Disconnect the test section (bypass) line fitting (see Figure 3-27B).
FIGURE 3-27
TEST-SECTION LINE REMOVAL
A B
Outlet Line
Bulkhead
Heater Section
(Bypass) Line
Test Section Fitting
Outlet Line
Fitting
8. Lift and rotate the thermocouple retaining clip (Figure 3-28) off the
thermocouple and carefully pull the thermocouple straight up out of the heater
tube taking care not to bend the thermocouple.
FIGURE 3-28
THERMOCOUPLE REMOVAL
Heater-Tube
Thermocouple
Connector
Heater-Tube
Heater-Tube
Thermocouple
Thermocouple
Hold-Down Clamp
9. Use the hex wrench provided to remove one of the cap screws from the upper
and lower bus bars.

10. Loosen the other screw on the bus bars three or four turns each, but do not
remove the screw. The end caps are not removed to insure they are not placed
on the wrong bus bars during reassembly.
11. Rotate the bus caps and remove the heater tube test section as shown in
Figure 3-29.
FIGURE 3-29
HEATER TUBE TEST SECTION REMOVAL
Upper Bus-Bar
End Cap
Lower Bus-Bar
End Cap
12. Use the extraction tool provided to remove the used o-ring and test filter
from the discharge chamber as shown in Figure 3-30. Discard the used o-ring
and filter.
FIGURE 3-30
DP-FILTER AND O-RING REMOVAL
Used DP Filter
Extraction
Tool
Used O-Ring
13. Remove the hex nuts and shoulder insulators.
CAUTION: Handle the heater tube by the ends only. Do not touch the center section of
the heater tube.
CAUTION: Do not allow the heater tube center section to contact the test section during
removal.

CAUTION: Do not reuse heater tubes. Tests indicate that magnesium migrates to eh
heater tube surface under tests conditions. Surface magnesium may reduce
adhesion of deposits to the heater tube surface
14. Carefully, slide the heater tube out of the test section Remove and discard the
o-rings. Save the insulator bushings and nuts.
15. Hold the heater tube so that it points upward from the fingers as shown in
Figure 3-31. Flush the heater tube with solvent.
FIGURE 3-31
HEATER TUBE FLUSHING
Heater Tube
Solvent
(N-Heptane)
16. After the solvent has evaporated from the heater tube, place the heater tube in
the original plastic container and seal it with a cap. Mark it with the
appropriate identification. Rate the heater tube. Follow the procedure “Heater
Tube Deposit Rating” in Appendix 3-C if using a visual tuberater.

3.6 SHUTDOWN
CAUTION: In case of emergencies, switch off the power at the back of the JFTOT III
enclosure or unplug the power cord from the wall outlet.
To completely power down the JFTOT III for an extended period of time, or
whenever necessary, perform the following steps:
1. From the Main Menu, press or click the EXIT PROGRAM button to close the
JFTOT III program and display the MS Windows desktop screen.
2. Press or click the START button in the lower left corner and perform the
standard MS Windows shut-down steps to power off the computer.
3. After the computer is shut down, switch the JFTOT III power switch in the
back panel to OFF.

ALCOR JFTOT III Users Manual Appendix 3-A: JFTOTIII Screen Descriptions
APPENDIX 3-A:
JFTOT III SCREEN DESCRIPTIONS
3-A.1 JFTOT III MENU STRUCTURE
The JFTOT III is designed to perform tests automatically after minor setup
procedures have been performed by the user. The following menu structure can be
used as an aid in navigating through the JFTOT III screen displays.
Main Screen
• DEFAULT Test
• Set Parameters (Maintenance Mode)
• Run Test
• Custom Test
• Setpoint Screen
• File Name for test data
• Auto Setup Progress screen
• Test Results screen
• Save Test option
• Test Annotation data entry screen
• Maintenance Menu Options Screen
• Aeration Pump ON/OFF
• Drive Pump ON/OFF and Flow Control set point
• System Vent-Valve Solenoid ON/OFF
• DP+ Vent-Valve Solenoid ON/OFF
• DP – Vent-Valve Solenoid ON/OFF
• DP Bypass-Valve Solenoid ON/OFF
• Bus Heater ON/OFF
• Setup DEFAULT Test
• Set-point values for temperature, time and flow rate
• Replace old file option
• Auto-Calibration Screen
• Calibrate System Pressure
• System Pressure Calibration Screen (follow prompts)
• Calibrate Differential Pressure
• Differential Pressure Calibration Screen (follow prompts)
• Calibrate Heater-Tube Thermocouple
• Heater-Tube Thermocouple Calibration Screen(follow prompts)
• Replace last calibration file option
• Reports
• Traditional Report
• Custom Report

ALCOR JFTOT III Users Manual Appendix 3-A: JFTOT III Screen Descriptions
3-A.2 JFTOT III MAIN SCREEN DESCRIPTION
CAUTION: Become familiar with the location and use of all controls, indicators,
connections, and accessories. Carefully read all instructions, warnings
cautions and labels prior to operating any portion of the system. Failure to
do so could result in personal injury and equipment damage.
The components of JFTOT III Main Screen shown in Figure 3-A-1 are listed and
described below.
FIGURE 3-A-1
JFTOT III MAIN SCREEN
3-A.2.1 MAIN SCREEN TOP SECTION

The top of the main screen includes the JFTOT III version number and PAC address.
The screen header contains the “Measure” number followed by the current date,
time and “Test” number as described in the following subsections.
3-A.2.1.1 JFTOT III Version

The JFTOT III software version is displayed at the top left corner of
the main screen. This number is updated when new versions of
JFTOT III software are installed.

3-A.2.1.2 Machine Number

A unique identification number can be assigned for each JFTOT III
for reference purposes. The number is assigned by the user during the
initial startup procedure. Any combination of alpha or numeric
characters can be entered for the number. The number can be
modified by any user.
3-A.2.1.3 Measure
The measure number indicates the speed at which all of the
parameters are being measured. The counter increments each time all
of the parameters have been measured (about 150 times per sec).
3-A.2.1.4 Date and Time

A system clock is displayed at the top of the screen that gives the
current date and time.
3-A.2.1.5 Test
Indicates the number of times the measured parameters are being
checked for errors during a test.
3-A.2.2 MAIN SCREEN LEFT PANEL

The panel located at the left of the main screen under the ALCOR logo includes an
automatically updated display of the date the previous auto calibration took place
and six option buttons which are described in the following subsections.
Refer to Figure 3-A-1 for locations.
3-A.2.2.1 Auto-Cal Date

The date the auto-calibration file was last updated is displayed
for reference.
3-A.2.2.2 Run Default Button

Pressing the Run Default Test button will automatically start
the default test. This test option is used for labs that run the
same test on each sample. For example, the D3241 test.
You can setup the parameters for this test by pressing the
Maintenance button on the main screen and then pressing the
Setup Default Test button on the maintenance screen. A
window will open for you to enter Test Time, Temperature and
Flow rate.
After setting the parameters, pressing the Run Default button
on the main menu screen will automatically run the default test
using these settings. The file name for the test data will be
automatically assigned as the next incrementing number. The
file name will be displayed above the temperature chart when
the test is running.

3-A.2.2.3 Run Custom Test

Press Run Custom button if you want to run a test that is
different than the Default test. You will be prompted for the test
parameters, temperature set point, test time, flow rate and file
name.
After the test is complete, you will be asked if you want to save
the data. If you say yes, then you will be prompted for Lab
information, Sample information, etc.
3-A.2.2.4 Maintenance
Press the Maintenance button on the main screen if you want
to operate the JFTOT III manually. You can turn on and off the
aeration pump, drive pump, and vent solenoids separately.
You can also open and close the DP bypass valve and turn on
the bus heater at a user-defined %Power (this is useful when
adjusting the SCR). Default test parameters are also set from
this screen.
Press the Maintenance button again on the Maintenance
screen to return to the main screen.
3-A.2.2.5 Auto Calibration

Press the Auto-Cal button if you need to calibrate the heater-
tube thermocouple or the pressure transducers.
If you go here and make any changes you will be asked if you
want to save the changes. If you answer yes then the "Auto-cal
date" will be changed accordingly.
3-A.2.2.6 Reports
Press the Reports button if you want to view the Test Data for
any test previously run, or if you want to create a custom
report.
3-A.2.2.7 Exit Program

Press the EXIT Program button if you want to exit from the
JFTOT III program and return to the MS Windows Desktop.
3-A.2.3 MAIN SCREEN RIGHT PANEL

The panel located at the right of the main screen under the PAC logo includes ten
digital indicators as described in the following subsections.

3-A.2.3.1 Flow mLpm

The “Flow mLpm” indicator displays the pump flow rate in
milliliters per minute. This flow rate is set by the default test
parameters or by the custom test parameters. These parameters
can be set from 0.000 to 9.999 mLpm.
3-A.2.3.2 Test Setpoint

The “Test Setpoint” indicator displays the temperature setpoint
of the current test, or if you are not currently running a test, it
displays the setpoint of the test that was previously run.
Click or press the up/down arrow control at the left of the
indicator to change the setpoint. The set point can be changed
slowly during a test if necessary.
3-A.2.3.3 Heater Tube Temp

The “Tube Temp” indicator displays the temperature of the
heater-tube thermocouple. The thermocouple must be
completely inside the heater tube to measure heater-tube
temperature.
NOTE: The test will abort if you accidentally start a test without inserting the
heater-tube thermocouple.
3-A.2.3.4 Bus-Bar Temp

The “Bus Bar” indicator displays the average temperature of the
top bus bar. It is used in error checking during a test.
If there is insufficient cooling during a test, the test will be
considered invalid and will abort.
3-A.2.3.5 Inlet Temp

The “Inlet Temp” indicator displays the temperature of the fuel
going into the test section. This temperature is also used for
error checking.
If the inlet fuel temperature is not within the limits described in
the ASTM D3241 method, the test will be considered invalid
and will abort.
3-A.2.3.6 Sys Pres

The “Sys Pres” indicator displays the current test fuel line
pressure. This value is used for error checking.
During a test this pressure must remain within the range
specified by the ASTM D3241 method or the test will be
considered invalid and will abort.

This pressure can be vented by selecting the Maintenance mode

and then pressing the system pressure vent control.
3-A.2.3.7 Diff Pres

The “Diff Pres” indicator displays the current differential
pressure across the DP filter. During a test the differential tare
value will be displayed. Tare indicates that the required time
has lapsed and that the Diff Pres indicator now displays a tared
value.
During a test, if this value exceeds the safety specification of the
differential pressure transducer, the bypass valve will be
activated and the pressure will drop to near zero.
3-A.2.3.8 Watts
The “Watts” indicator displays the power in Watts dissipated
by the heater tube. This value is used in error checking.
At a given flow rate the power required to heat an aluminum
heater tube to a given temperature is calculable. If the test
aborts because of the Watt value, a number of things could be
the cause.
• The heater tube is not clamped to the bus bars tightly.
• The heater tube has an out of tolerance ID or OD.
• The material the tube is made of is not within spec.
• The heater tube has been run previously at a high
temperature.
• The flow is not what it is supposed to be.
• The heater tube is shorting to the heater test section.
3-A.2.3.9 Tube Resistance

During a test the resistance of the tube is displayed. This value
is used in error checking.
If a test aborts because of heater-tube resistance, the following
things may be at fault.
• The bus bars are not making good contact with the heater
tube.
• The heater-tube ID, OD or material may be out of tolerance.
• The heater-tube that is shorting to the Heater Test section.
• The heater tube has been run previously at a high
temperature.
3-A.2.3.10 % power
The % Power indicator displays the % power that is being
applied by the SCR. This is set when the SCR calibration is
performed.
This value will be higher if the test setpoint is increased.

NOTE: If you run all of your tests at the same setpoint, the % power value should be
approximately the same from test to test. If this value increases over time it
may be an indication that there is some corrosion building up on the bus-bar
connections.
3-A.2.4 GRAPHICS AND MESSAGE PANELS

Two graphics panels and a message panel are located in the center of the main
display. The vertical and horizontal scales for the charts is set to automatically scale
as the plot section is magnified or reduced for better viewing. The center panels are
described in the following subsections.
3-A.2.4.1 Temperature Chart

Traces representing the bus-bar temperature (orange), heater-
tube temperature (red), and the inlet temperature (green) are
simultaneously displayed for the test in progress or for a stored
previous test.
The file name and path for the current test in progress or
recorded test is displayed at the top of the temperature chart.
The system assigns the next sequential number as the file name
for a new test.
3-A.2.4.2 Differential Pressure Chart

The differential pressure chart displays a chart of the
differential pressure that is developed across the differential
pressure
(DP) filter.
3-A.2.4.3 Chart Controls

After the test is complete, all of the data represented by the
charts can be manipulated by the chart controls at the top of the
charts as shown in Figure 3-A-2.
FIGURE 3-A-2
JFTOT III MAIN SCREEN CHART CONTROLS
Area of Chart to Magnify

Type of
Magnification Grab and Move
Grid Sections
When the button is pressed or clicked, three option buttons

appear that allow a choice of magnification (diverging arrows),
demagnification (converging arrows) and continuous
magnification and demagnification (magnifying glass under an
arching arrow).

When the button is pressed or clicked, three option buttons

appear that allow a choice of upper and/or central plot sections
for magnification.
When the button is pressed or clicked, a hand appears on the
plot to allow the grids to be “grabbed” and moved in order to
observe a different section of the plot.
The output plot and differential pressure sections of the main
menu can be changed by right-clicking on the chart section of
the screen to display an options box as shown in Figure 3-A-3.
FIGURE 3-A-3
JFTOT III MAIN SCREEN CHART – CONTROL BOX
The choices included in the option box are as follows:

• Reinitialize to Default Value: Resets scales to the original
(Default) values
• Cut, Copy or Paste Data: allows the user to remove, copy or
insert the values from one chart to another chart.
• Description and Tips: Provides helpful information
concerning the charts
• Visible Items: allows the user to perform the following:
• Plot Legend: change the legends for the plot
• Scale Legend: change the legends for a scale
• Graph Palette: change the graph palette
• Scrollbar: Not Available
• X Scale: Change the values for the X scale
• Y Scale: Change the values for the Y scale
• Unit Label: Change units used (inch, cm, mm, etc)

• Clear Chart: Allows the user to clear the entire chart

• AutoScale X and/ or AutoScale Y: Allows the user to choose
to make the X or Y or both X and Y axis to scale
automatically
You can also manipulate the scales by double-clicking on the
scale extremes and entering the value that you want.
NOTE: You cannot manipulate the chart while the test is running because the chart
has been set to auto-scale during a test.
3-A.2.4.4 Message Display

The lower panel displays error and general status text messages
such as the test time remaining, during a test and error
messages.
3-A.2.5 HELP
HELP information is available for all screen areas and controls by pressing the
CTL and H keys at the same time and then positioning the cursor over the screen
area or control in question. An information box appears (Figure 3-A-4) with an
explanation of the control function. Pressing the CTL and H keys again clears the
HELP function and returns the JFTOT III to normal operation.
FIGURE 3-A-4
JFTOT III MAIN SCREEN – HELP (EXAMPLE)


ALCOR JFTOT III Users Manual Appendix 3-B: JFTOT III Operation Details
APPENDIX 3-B:
JFTOT III OPERATION DETAILS
3-B.1 OVERVIEW
The JFTOT III is designed to automatically run tests with minimal operator
involvement. After the setup procedures have been performed, either Default or
Custom test modes can be selected for running tests automatically. Maintenance
mode allows the user to operate individual components separately for tests and
adjustments. The Auto Cal mode is used to calibrate system pressure, differential
pressure, and heater-tube thermocouple. Test data from previous tests can be viewed
and new custom reports created in the Reports mode.
The test operation allows an operator to setup and run a thermal oxidation test. Two
test selections are provided, CUSTOM and D3241 DEFAULT. The CUSTOM test
allows the operator to adjust many of the test parameters. This provides a means to
design a custom non-ASTM thermal oxidation test. The user-adjustable parameters
are initially set to the values required by ASTM D3241, so the CUSTOM test can be
used to run a test as specified by ASTM D3241 until parameters are changed.
The D3241 Default test is basically the same as the CUSTOM test except that most of
the test parameters are fixed as specified by ASTM D3241. The following parameters
in Table 3-B-1 are fixed in the D3241 default test but variable in the custom test.
TABLE 3-B-1
TEST SETTINGS
Parameter D3241 Default Custom Default

Test Settings Test Settings
Flowrate 3.0ml/min 1.0 to 10.0ml/min
Test Time 150 min 4 to Unlimited min
3-B.1.1 RUN D3241 TEST (DEFAULT TEST)

The default test is the simplest test for an operator to run. It can be used for labs that
run the same test with established parameters on many different fuel samples. For
example: ASTM D3241 (See Quick Start Guide for abbreviated ASTM D3241 test
procedures).
The file name for the test data will be automatically assigned an incrementing
number (D1 through DXXXXXXXX).
The file name will be displayed above the temperature chart when the test is run.
The Test data will be stored on the hard drive in spreadsheet format in the
C:/JFTOT III/ test_data/ directory.
You can store as many tests as free space on the JFTOT III hard drive will allow.
If the parameters for the default test need to be changed, refer to Section 3-B.1.3.
“Test Setup Parameters”.
Perform the following procedure to setup and/or run a default test.

1. Press or click the RUN DEFAULT button on the main screen. The Test
Annotation Dialog box appears as shown in Figure 3-B-2A.
FIGURE 3-B-1
2. Fill in the blanks and then click OK.

3. An instruction box (Figure 3-B-2B) will appear prompting you to perform
setup.
4. Follow the setup instructions on the prompt shown in Figure 3-B-2.
NOTE: Refer to Sections 3.3 and 3.4 for detailed cleaning and setup instructions.
FIGURE 3-B-2A FIGURE 3-B-2B

ANNOTATION DIALOG BOX SETUP PROCEDURE INSTRUCTION BOX

NOTE: System Pressure and RH adjustments should be verified before starting the
tests (see “JFTOT III Adjustments” in Section 5.4).
The system will start a preparation process automatically, which includes the
following operations.
• Aerating the sample
• Purging the system
• Measuring the relative humidity of the air supply
• Measuring the differential pressure across the DP filter
• Pressurizing the system
The system fuel pressure will increase. As the pressure builds up, no fuel will drip
from the sample out line.
A progress panel (Figure 3-B-3) will appear that displays the progress of the
auto-preparation process.
FIGURE 3-B-3
PROGRESS PANEL
NOTE: The progress panel will prompt the operator to check the drive pump flow
rate at 9.999mlpm and at the test flow rate. If either of these two flow rates
are incorrect, you will have two minutes to correct the problem or prime the
pump (see Section 5.4.2) If you wish to abort the test, press or click the
ABORT button. To skip this pretest procedure, press the SKIP button.
The progress popup panel provides the following information.

• Minutes Remain: Digital readout of the minutes remaining until the auto-
preparation procedure completes and the test begins
• Laps Time: Amount of time in minutes that has lapsed since the test began.
• Aeration % RH: The relative humidity reading of the air supplied to the
sample.
• Differential Pressure: Pressure across the DP filter displayed in mmHg
• System Pressure: Digital display of the system pressure given as mmHg
The overall progress of the auto preparation process is displayed as a red horizontal
progress bar.
The auto-preparation process is displayed by five green indicators that light after the
displayed operation has begun. The indicators should light in sequence as follows:
• Drive Pump: Indicates the sample drive pump is on when lit.
• Aeration Pump: Indicates the aeration pump is on when lit.
• System Vent: Indicates the system vent solenoid controlled valve is energized
(open) when lit.
• DP + Vent: Indicates the DP + vent solenoid-controlled valve is energized
(open) when lit.
• DP – Vent: Indicates the DP – vent solenoid-controlled valve is energized
(open) when lit.
If these operations complete without error, then the test will start automatically. If
there is an error, you will be prompted concerning the nature of the error and the
possible causes.
The JFTOT III program automatically begins the test and displays the test-in-
progress screen shown in Figure 3-B-4. The green Test Running indicator lamp
should be lit to confirm the test is running.
Sample inlet temperature (green), heater-tube temperature (yellow), and bus-bar
temperature (red) are plotted in the upper graphics panel and Differential pressure is
plotted in the lower graphics panel.
A green “Tare” indicator is on to indicate that the required time has lapsed and that
the Diff Pres indicator now displays a tared value.
The remaining time before test completion is displayed in the message panel at the
bottom of the screen.
If for any reason you want to stop the test before the test has finished, press or click
the STOP TEST control located in the test screen.
NOTE: A watchdog timer is used by JFTOT III to monitor program activity. If for
some reason the PC locks up or the program simply stops running, the
watchdog timer will remove power from the hardware and completely vent
the pressure from the system.

FIGURE 3-B-4
TEST IN PROGRESS SCREEN
A file was created and a number was assigned automatically to the file name when
the test began.
When the test has finished, a small option box will appear (Figure 3-B-5) and prompt
you to save the file containing the test data. Press or click YES to save the file or NO
if the data is to be deleted. IF YES is selected, the Traditional Report Form will
automatically display. See the Traditional Reports in Section 3-B.1.2 and
Figure 3-B-7 for information on filling out the Traditional Report. If NO is selected
the system returns to the Main Screen.
FIGURE 3-B-5
SAVE FILE OPTION BOX
3-B.1.2 REPORTS
Default test and Custom test results are automatically entered into a report form that
can be viewed and printed directly from the JFTOT III. Either a Traditional Report
or a Custom Report format can be used. When the REPORTS button on the main
screen is pressed or clicked, a panel is displayed with buttons for selecting either a
traditional or a custom report as shown in Figure 3-B-6. A third button allows the
user to cancel the report mode and return to the main screen.

FIGURE 3-B-6
REPORT SELECTION BOX
3-B.1.2.1 Traditional Report

If the Traditional Report is selected, the Traditional Report
form is displayed as shown in Figure 3-B-7. The Traditional
Report form is automatically displayed after the default test has
completed.
If information is missing from the form, the TAB key on the
keyboard can be used to move the cursor to the blank box. Text
can then be keyed into the blank box from the keyboard.
When the report contains all of the required information touch
or click the OK button. The Traditional report will
automatically be printed by the local or network default printer
attached to the JFTOT III computer.
FIGURE 3-B-7
TRADITIONAL REPORT (EXAMPLE)

3-B.1.2.2 Custom Report

If you selected the “Custom” report option, a file selection
window will open as shown in Figure 3-B-8. Here you can select
the data file containing the test for which you want to make a
custom report. The Custom report can be created with any
“Spreadsheet software”. The test data files are standard tab-
delimited files. If you use the file extension for the type of
spreadsheet software that you have when you name the data
file, then it will open automatically when you double click it
here.
FIGURE 3-B-8
CUSTOM REPORT FILE SELECTION SCREEN (EXAMPLE)
A sample spreadsheet test data report from a custom report file

is shown in Figure 3-B-9.
FIGURE 3-B-9
SPREADSHEET TEST DATA REPORT (EXAMPLE)

Perform the procedures in Section 3-5 “Disassembly” to clean

up after a test. If no more test are to be run, refer to Section 3-6
“Shutdown” to shutdown the JFTOT III.
3-B.1.3 TEST SETUP PARAMETERS

The JFTOT III was setup at the factory to run the ASTM D3241 Test as the
default test. When a new default test is to be run, you can change these parameters
as required by your test method.
The test can be setup to run at any setpoint from 100°C to 380°C, at any flow rate
from 0.001 mLmp to 9.999 mLpm and any time limited only by the sample size and
flow rate.
To change the parameters for the default test, perform the following steps.
1. From the main screen, press or click the MAINT button as shown in
Figure 3-B-10.
FIGURE 3-B-10
MAIN SCREEN – MAINT BUTTON
2. From the Maintenance screen, press or click the SETUP DEFAULT TEST button
as shown in Figure 3-B-11.

FIGURE 3-B-11
MAINTENANCE SCREEN – SETUP DEFAULT TEST BUTTON
3. After a small window appears as shown in Figure 3-B-12, double click on the
TEST TEMPERATURE button and type in the desired test temperature or click
the control at the left of the value.
FIGURE 3-B-12
MAINTENANCE SCREEN – PARAMETER SETTINGS
4. Double click on the TEST TIME IN MINUTES button and type in the desired test
time or click the control at the left of the value.
5. Double click on the FLOW RATE IN MLPM button and type in the desired
flow rate or click the control at the left of the value.
6. Press the OK button to save the settings and return to the maintenance menu.

7. After a prompt appears (Figure 3-B-13) asking if you want to replace the old
file, press or click the REPLACE button to replace the previous test file with the
new test file. Press or click the CANCEL button to discard the new settings and
keep the original settings for the Default tests.
FIGURE 3-B-13
MAINTENANCE SCREEN – FILE REPLACEMENT OPTION BOX
The Default test is now in place. This is the test that will run each time the
DEFAULT TEST button in the main screen is pressed. Follow this same procedure if
you want to change the default test again.
8. Press the EXIT button to return the main screen.
3-B.1.4 RUN A CUSTOM TEST

When a test is to be run that is not to be used on a consistent basis like the Default
test, the new test is considered to be a Custom test that is assigned a unique file name
by the person conducting the test during setup.
The file name will be displayed above the temperature chart when the test is run.
The test data will be stored on the hard drive in spreadsheet format in the C:/JFTOT
III/ test_data/ directory.
You can store as many tests as free space on the JFTOT III hard drive will allow.
Perform the following procedure to setup and/or run a custom test.
1. Press or click the RUN CUSTOM button on the main screen as shown in
Figure 3-B-14. The Test Annotation screen (Figure 3B15A) appears.

FIGURE 3-B-14
JFTOT III MAIN SCREEN – RUN CUSTOM
2. Fill in the blanks I the Test Annotation screen and then click OK.
3. A pop-up instruction box appears (Figure 3-B-15B) prompting you to perform
setup procedures. Follow the setup instructions on the prompt before
continuing.
NOTE: Refer to the Setup Procedures in Section 3-3 and 3-4 for detailed cleaning
and assembly procedures.
FIGURE 3-B-15A FIGURE 3-B-15B

ANNOTATION DIALOG BOX SETUP PROCEDURE INSTRUCTION BOX
5. After a small window appears as shown in Figure 3-B-16, double click on the
TEST TEMPERATURE button and type in the desired test temperature.

FIGURE 3-B-16
MAINTENANCE SCREEN – PARAMETER SETTINGS
6. Double click on the TEST TIME IN MINUTES button and type in the desired
test time.
7. Double click on the FLOW RATE IN MLPM button and type in the desired
flow rate.
8. Press the OK button to save the settings.
9. After a prompt appears (Figure 3-B-17) prompting you for a new file name,
double click on the file name space and enter the new file name.
(e.g., Test 9-10-05)
FIGURE 3-B-17
FILE NAME INPUT BOX
10. Press the OK button to save the file name.

The system will start a preparation process automatically, which includes the
following operations.
• Aerating the sample
• Purging the system
• Measuring the relative humidity of the air supply
• Measuring the differential pressure across the DP filter

• Pressurizing the system
This procedure usually takes about 6 minutes for completion.

A popup progress panel (Figure 3-B-18) will appear that displays the progress of the
auto-preparation process.
FIGURE 3-B-18
AUTO-PREPARATION PROGRESS PANEL
NOTE: The progress panel will prompt the operator to check the drive pump flow
rate at 9.999mlpm and at the test flow rate. If either of these two flow rates
are incorrect, you will have two minutes to correct the problem or prime the
pump (see Section 5.4.2). If you wish to abort the test press or click the
ABORT button. To skip this pretest procedure, press the SKIP button.
The progress panel provides the following information.

• Minutes Remain: Digital readout of the minutes remaining until the auto-
preparation procedure completes and the test begins
• Laps Time: Amount of time that has lapsed since the test began.
• Aeration % RH: The relative humidity reading of the air supplied to the
sample.
• Differential Pressure: Pressure across the DP filter displayed in mmHg
• System Pressure: Digital display of the system pressure given as mmHg
The overall progress of the auto preparation process is displayed as a red horizontal
progress bar.
The auto-preparation process is displayed by five green indicators that light after the
displayed operation has begun. The indicators should light in sequence as follows:
• Drive Pump: Indicates the sample drive pump is on when lit.
• Aeration Pump: Indicates the aeration pump is on when lit.

• System Vent: Indicates the system vent solenoid-controlled valve is energized

(open) when lit.
• DP + Vent: Indicates the DP + vent solenoid- controlled valve is energized
(open) when lit.
• DP – Vent: Indicates the DP – vent solenoid-controlled valve is energized
(open) when lit.
If these operations complete without error, then the test will start automatically.
If there is an error, you will be prompted concerning the nature of the error and the
possible causes.
The JFTOT III program automatically begins the test and displays the test-in-
progress screen shown in Figure 3-B-19. The green Test Running indicator lamp
should be lit to confirm the test is running.
FIGURE 3-B-19
TEST IN PROGRESS SCREEN
Heater-Tube
Temperature (Red)
Bus-Bar Temperature (Orange)

Test Running
(Green) Inlet Temperature (Green)
Tare (Green)
DP Pressure (Yellow)
Sample inlet temperature (green), bus-bar temperature (orange) and heater-tube

temperature (red) are plotted in the upper graphics panel and differential pressure is
plotted in the lower graphics panel. A green “Tare” indicator is on to indicate that
the required time has lapsed and that the Diff Press indicator now displays a tared
valve.
The remaining time before test completion is displayed in the message panel at the
bottom of the screen.
If for any reason you want to stop the test before the test has finished, press or click
the STOP TEST button located in the test screen.
A file was created when the test began and a number was assigned automatically to
the file name. When the test has finished a small window (Figure 3-B-20) will appear
and prompt you to save the file containing the test data. Press or click YES to save
the file or NO if the data is to be deleted.

FIGURE 3-B-20
SAVE FILE OPTION BOX
If you press or click the YES button, the Traditional Report screen (Figure 3-B-21)
will appear. Fill in any missing dat. Double click on each of the controls that you
want to enter data into, touch, click or use TAB key to select the control, and type in
the data. When you are finished, press or click on the OK button. The report will be
printed automatically.
FIGURE 3-B-21
TRADITIONAL REPORT (EXAMPLE)
The test is now complete and the test data has been saved. Refer to “Reports” in
Section 3-B.1.2 to print a report of the saved test results.

3-B.1.5 MAINTENANCE
The Maintenance mode is used to actuate and test individual components in the
JFTOT III separately without affecting other components. Select the Maintenance
option from the Main screen to display the screen shown in Figure 3-B-22.
FIGURE 3-B-22
JFTOT III MAINTENANCE SCREEN
The main control panel components in the Maintenance menu (Figure 3-B-22) are as
follows:
• Aeration Pump ON/OFF: Pressing the AERATION button lights the button
(yellow), changes the ON/OFF indicator to ON (green) and starts the aeration
pump. Pressing the AERATION button again returns the ON/OFF indicator to
OFF and stops the pump.
• Drive Pump ON/OFF: pressing the DRIVE PUMP button lights the button
(yellow), changes the ON/OFF indicator to ON (green) and starts the drive
pump. Pressing the DRIVE PUMP button again returns the ON/OFF indicator to
OFF and stops the pump.
• System Vent ON/OFF: pressing the SYSTEM VENT button lights the button
(yellow), changes the ON/OFF indicator to ON (green) and opens the system
vent valve. Pressing the SYSTEM VENT button again returns the ON/OFF
indicator to OFF and closes the valve.
• DP + Vent ON/OFF: pressing the DP + VENT button lights the button
(yellow), changes the ON/OFF indicator to ON (green) and opens the DP +
vent valve. Pressing the DP + VENT button again returns the ON/OFF
• DP – Vent ON/OFF: pressing the DP – VENT button lights the button
(yellow), changes the ON/OFF indicator to ON (green) and opens the DP –
vent valve. Pressing the DP – VENT button again, returns the ON/OFF indicator
to OFF and closes the valve.

• DP Bypass Valve ON/OFF: pressing the DP BYPASS button lights the button
(yellow), changes the ON/OFF indicator to ON (green) and opens the DP
bypass valve. Pressing the DP BYPASS button again, returns the ON/OFF
• Bus Heater ON/OFF: pressing the BUS HEATER button lights the button
(yellow), changes the ON/OFF indicator to ON (green) and applies power
through the bus bar to heat the heater tube. Pressing the BUS HEATER button
again returns the ON/OFF indicator to OFF and removes power to the bus bar.
• % RH: displays a digital value for the % relative humidity (RH) for the sample
air supply
• FLOW: displays a digital value for the sample flow rate in millimeters per
minute (mmpm) and allows the drive pump output flow rate to be changed
manually from 0.01 to 9.99 mlpm by pressing or clicking on the control button
on the left after pressing or clicking the DRV PMP OFF button.
NOTE: The drive pump will not start until the flow value is incremented or
decremented.
• Setup Default Test: Pressing the SETUP DEFAULT button will allow the
parameters to be set for a new default test.
• % pwr: The percentage of the total power available to be applied to the bus bar
can be controlled from 0-100% power by pressing or clicking the button to the
left of the % pwr display and observing the digital reading.
CAUTION: Entering too high % power increments will melt the heater tube. Enter small
changes starting at a low % value (e.g. 2 %, 4%, etc).
• Millivolts: The voltage being applied to the bus bar can be monitored by
observing the digital reading in millivolts
Perform the following steps to activate the components in the maintenance mode.
1. Press or click the MAINT button on the main screen as shown in
Figure 3-B-23.

FIGURE 3-B-23
2. From the maintenance screen, press the button for desired function as shown
in Figure 3-B-24 and listed in the following procedures.
WARNING: It is possible to create a hazardous condition by turning on a piece of

hardware at too high of a value. Always use a small value and increment up
to the desired value.
FIGURE 3-B-24
JFTOTIII MAINTENANCE SCREEN – AERATION
3-B.1.5.1 Aeration
The aeration system can be checked independently by
performing the following steps.

CAUTION: To avoid possible pressure build-up, open the AERATION FLOW rotometer
control valve approximately 1/8 turn before turning on pump. After the test
is started, adjust the AERATION FLOW rotometer to the center of the
green range.
1. From the Maintenance Screen, click or touch the

AERATION button (ON/OFF). The air pump should
turn on.
2. Adjust the air flow meter, located at the upper left of the
bus bar assembly, to the green area on the airflow control
inside of the bus-bar compartment (See Section 5.1.3 for
location).
3. After the air pump has been operating for at least one-
minute, check that the %RH reads below 20%. If the
%RH does not read below 20%, the dry-rite crystals need
to be changed or the 5VDC reference voltage needs to be
adjusted.
NOTE: The program looks at the %RH during the aeration portion of the JFTOT III
test and will not allow the test to continue if the %RH is above 20%.
3-B.1.5.2 Drive Pump

Touching or clicking Drive Pump button (ON/OFF) will turn
the Drive pump on at the flow-rate that has been entered into
the “FLOW” control at the left of the flow display as shown in
Figure 3-B-25.
FIGURE 3-B-25
JFTOT III MAINTENANCE SCREEN – DRIVE PUMP

To initially start the drive at a known flow-rate, you must enter

a value into the “FLOW” control on the maintenance screen
and then turn the drive pump on. To change pump flow-rates
after that, simply enter a new value into the “FLOW” control.
The drive pump has the capability of pumping the sample at
flow rates from .001 to 9.999 mlpm. Values entered into the
“FLOW” control that are not within this range are changed to
the nearest value within the valid range.
3-B.1.5.3 Sys Vent

When the drive pump is on at some flow rate, the flow goes
from the drive pump through a back-pressure regulator and
pressure is built up, depending on the back-pressure regulator
setting.
When the Sys Vent button (ON/OFF) is touched or clicked, a
solenoid controlled valve will activate venting any pressure that
has built up in the system directly to the purge-out line in the
sample compartment.
You can use this control to vent any pressure in the system, or
if you want to run the drive pump under no pressure
conditions.
For example, if an air bubble is caught in one of the check valves on
the drive pump, and you need to prime the drive pump, it is easier to
prime the pump under no pressure conditions
3-B.1.5.4 DP+ Vent and DP – Vent

Pressing or clicking the DP+ Vent or DP– Vent button
(ON/OFF) activates a solenoid-controlled valve that vents
pressure from the differential pressure transducer. The DP+
and DP– controls work the same as the Sys Vent control except
that when one of these controls are activated, the drive pump
flow is directed through the positive or negative side of the
differential pressure transducer directly to the purge out line in
the sample compartment.
These controls are used to purge any air from the differential
pressure transducer that might cause an erroneous reading.
NOTE: During a test the positive and negative sides of the differential pressure
transducer are purged automatically. The only time that you need to use
these controls is when you are performing a DP standardization test or if a
new differential pressure transducer has been installed.

3-B.1.5.5 DP Bypass
Pressing or clicking the DP-Bypass button (ON/OFF) activates a
solenoid-controlled valve that is used during test time to protect
the differential pressure transducer from pressures that may
damage the transducer. The solenoid-controlled valve is
connected between the positive and negative ports of the
transducer and when solenoid is activated, it equalizes the
pressure between the two ports.
You can use this control to check the operation of the bypass
solenoid and to check a new solenoid if it has to be replaced.
3-B.1.5.6 Bus Heater

Pressing or clicking the Bus-Heater button (ON-OFF) turns on
the bus heater at the selected % power setting.
CAUTION: Check the % power setting before turning on the bus heater. Entering too
high % power increments will melt the heater tube. Enter small changes
starting at a low % value (e.g. 2 %, 4%, etc).
After the thermocouple is installed into the heater tube, the %

power can be increased or decreased by either pressing the
arrow control at the left of the % power display box or by
clicking inside the display box and entering a value from the
keyboard. Tube Temperature readout on the right of the screen
must be closely monitored to assure the temperature is kept less
than 380° C.
CAUTION: Keep the tube temperature below 380°C at all times. Failure to do so can
result in a meltdown of the heater tube

ALCOR JFTOT III Users Manual Appendix 3-C: Heater Tube Deposit Ratings
APPENDIX 3-C:
HEATER TUBE DEPOSIT RATING
3-C.1 VISUAL TUBERATER OPERATION
This procedure requires the Visual Tuberator light box equipped with a magnifying-
glass assembly and ASTM color chart standard.
NOTE: Make certain all (three) bulbs in the Tuberator are functioning to assure
consistent ratings.
NOTE: Do not touch the center section of the heater tube.
1. Snap the upper end of the heater tube into the clamp of the adapter for the
heater tube as shown in Figure 3-C-1.
FIGURE 3-C-1
HEATER TUBE/TUBERATOR ADAPTER INSTALLATION
Heater Heater
Tube Tube
Adapter
Serial Number
2. Push the heater tube against the stop of the heater tube adapter.
3. Slide the adapter with the heater tube over the guide rod into the Tuberator as
shown in Figure 3-C-2.
FIGURE 3-C-2
TUBERATOR HEATER TUBE AND ADAPTER INSTALLATION
Heater
Tube and
Adapter
Visual
Tuberator
Light Box
4. Insert the ASTM Color Standard horizontally into the back of the Tuberator
in the slot provided as shown in Figure 3-C-3.

Revision B Page 3C-1
NOTE: The Tuberator color standard is known to fade upon exposure to strong
light. The life of the Standard is not known, but a separate standard plate
can be stored in the dark and compared to the Standard routinely used.
FIGURE 3-C-3
COLOR STANDARD INSTALLATION
ASTM
Tuberator
Color
Viewing
Standard
Port
NOTE: Only qualified personnel having normal eyesight and abilities to distinguish
between subtle color variances should be allowed to rate tubes.
5. Rotate the adapter and position the heater tube such that the side with the
maximum deposit is visible. If necessary, remove adapter and rotate heater
tube slightly in holder to better reveal the maximum deposit.
6. Compare the maximum heater tube deposit with the ASTM Color Standard as
shown in Figure 3-C-4. When the maximum deposit corresponds exactly to a
color standard, that number should be recorded. If the maximum heater tube
deposit being rated is in the obvious transition state between any two adjacent
color standards, the rating should be reported as less than the darker (the
higher number) standard.
FIGURE 3-C-4
HEATER TUBE TUBERATOR COLOR STANDARD COMPARISON
Heater Tube
ASTM Color
Standard
ASTM Color
Standard
Heater Tube
Adapter

Page 3C-2 Revision B
7. In the event the heater tube has deposits which do not match the normal Color
Standard colors, then use the following rules for rating. With reference to
standard terms:
• If the deposit is “peacock” color, rate this as “Code P”, but also rate any
deposit that shows normal deposit color.
NOTE: The term “Peacock” refers to a multicolored, rainbow-like deposit color

caused by interference phenomena when deposit thickness exceeds the
quarter-wavelength of visible light.
• If the deposit contains an abnormal color, rate this as “Code A”, but
also rate any deposit that shows normal deposit color.
NOTE: “Abnormal Color” is a tube deposit color such as blue or grey which is
neither peacock nor does it match the color standard.
8. When reporting the overall rating, report the maximum rating as described in
step 6, and if there are present colors which do not match the Color Standard,
report these as well. If there are only “P” and/or “A” deposits, report only
these and do not attempt to estimate a numerical grade.
• Example 1: a heater tube has a maximum deposit falling between Color
Standard Codes 2 and 3 with no other colors present. The overall
heater-tube rating would be “less than 3”.
• Example 2: the darkest deposit on a heater tube matches a Code 3, but
there is also a “peacock” deposit present. The overall rating of the
heater tube would be reported as “3P”.
• Example 3: a heater tube has a deposit that matches Color Standard
Code 1 and also has an abnormal deposit. The overall tube rating would
be reported as “1A”.
9. Return the heater tube to its original container.

3-C.2 VIDEO TUBE-DEPOSIT RATER OPERATION

This procedure requires the Video Tube Deposit Rater (Video TDR) and ASTM
color chart standard.
Steps for operating the standalone Video TDR model are described in this procedure.
Procedures for operating the Video TDR when connected to a PC are provided in the
Video TDR User’s Manual.
1. Power on the Video TDR and wait for the LCD readout “WAIT FOR
CHART”.
FIGURE 3-C-5
VIDEO TDR POWER ON
LCD START
Screen Push
Button
Analysis
Chamber
Door
2. Open the door to the analysis chamber (Figure 3-C-6) and check for presence
of a heater tube or color chart. Remove heater tube if installed.
NOTE: Ensure the end of the chart marked DOWN is toward the bottom of the
enclosure.
FIGURE 3-C-6
VIDEO TDR ANALYSIS CHAMBER
Heater
Tube ASTM
Location Color Chart
Location

3. If a color chart is not in place, insert the chart into the chart holder as shown
in Figure 3-C-7. There must be no heater tube installed.
FIGURE 3-C-7
ASTM COLOR CHART INSTALLATION
ASTM
Color Chart
Color
Chart
Holder
“DOWN”
Label
Stepping
Motor
Assembly
4. Close the door and press the START button on the top of the VTDR. The
chart image is recorded and saved in memory by the computer.
NOTE: If the chart analysis fails, the LCD displays CHART CAPTURE FAILURE.
Failures are sometimes due to incorrect light levels or a heater tube may be
installed.
5. After the chart analysis has completed successfully, the LCD will display
CHART OK.
6. Press the START button to set the VDTR for the tube analysis.
7. The LCD will show READY to indicate the VTDR is ready to analyze a heater
tube.
CAUTION: Handle the heater tube by the ends only. Never touch the center section of
the heater tube.
8. Open the door to the analysis chamber and install the heater tube as follows:
8.1. Pull out the knob of the spring-loaded clamping mechanism at the top of
the tube holder as shown in Figure 3-C-8.

FIGURE 3-C-8
HEATER TUBE INSTALLATION
Serial
Number End
of Heater
Stepping
Motor Spring-Loaded
Assembly Clamping
Mechanism
8.2 Place the unmarked (no serial numbers) end of the heater tube into the
bottom end of the holder.
8.3 Lower the serial-numbered end of the tube down into the top end of the
holder and slowly release the clamping mechanism into the end of the
tube.
CAUTION: The end of the heater tube with the etched serial numbers should be at the
top of the tube holder with the serial numbers not facing directly upwards.
9. Close the door and then press the START button to begin the automatic tube
deposit rating test.
10. The LCD reports the status of the analysis by displaying the scan increments
as “SCANNING 1/36” through “SCANNING 36/36” (Figure 3-C-1A).
11. After the analysis is complete (6 seconds) the LCD indicates the results as
“RESULTS: 0” through “RESULTS: 4”. (Figure 3-C-1B).
FIGURE 3-C-1A FIGURE 3-C-1B
SCANNING RESULTS
11. Press the START button to clear the results for a new test.
NOTE: If the Video TDR is connected to a computer with VTDR software installed,
refer to the Video TDR User’s Manual for installation and operation of the
computerized version.

ALCOR JFTOT III Users Manual Appendix 3-D: Precautionary Statements for
Hazardous Materials
APPENDIX 3-D:
PRECAUTIONARY STATEMENTS
FOR HAZARDOUS MATERIALS
WARNING: The precautionary statements listed might not reference all aspects of the
material. For complete information, the user is urged to reference the
appropriate Material Safety Data Sheet (MSDS) for the particular material
being used.
3-D.1 ACETONE
• Keep away from heat, sparks, and open flame.
• Keep container closed. Use with adequate ventilation.
• Avoid buildup of vapors and eliminate sources of ignition, especially non-explosion
proof electrical apparatus and heaters.
3-D.2 TOLUENE
• Avoid prolonged or repeated breathing of vapor or spray mist.
• Use only with adequate ventilation.
• Eye irritation and dizziness are indications of overexposure.
• Do not take internally; swallowing may cause injury, illness, or death.
• Avoid prolonged or repeated contact with skin.
• Do not get in eyes.
• Produces toxic vapors on contact with flames, hot glowing surfaces, or electric arcs.
3-D.3 ISO-PROPANOL (2-PROPANOL)

• Keep container closed; use with adequate ventilation.
• Avoid buildup of vapors and eliminate sources of ignition, especially non-explosion
• Eye irritation and dizziness are indications of overexposure.
• Do not take internally; swallowing may cause injury, illness, or death.
• Do not get in eyes.
• Produce toxic vapors on contact with flames, hot glowing surfaces, or electric arcs.

Revision B Page 3D-1
ALCOR JFTOT III Users Manual Appendix 3-D: Precautionary Statements for
Hazardous Materials
3-D.4 N-HEPTANE
• Keep container closed.
• Use with adequate ventilation.
• Avoid prolonged or repeated contact with skin
3-D.5 2,2,4-TRIMETHYL PENTANE TECHNICAL GRADE (ISO-OCTANE)

• Keep container closed; use with adequate ventilation.
• Avoid buildup of vapors and eliminate sources of ignition, especially nonexplosion-
• Avoid prolonged or repeated contact with skin
3-D.6 AVIATION TURBINE FUEL

(JET A OR A-1, JET B, SEE ASTM SPECIFICATION D 1655)
• Keep container closed.
• Use with adequate ventilation.
• Avoid buildup of vapors and eliminate sources of ignition, especially nonexplosion-
• Avoid breathing vapor or spray mist.

Page 3D-2 Revision B
JFTOT 230
MARK III
USER’S MANUAL
SECTION 4: CALIBRATION
PN: AL-59322
Revision B


05.18.06
REVISION HISTORY
SECTION 4: CALIBRATION ................................................................................................. 1
4.1 Overview....................................................................................................................... 1
4.2 Calibration Procedures ................................................................................................. 2
4.2.1 Temperature Calibration........................................................................................................2
4.2.2 System Pressure Transducer Calibration..............................................................................9
4.2.3 DP Transducer Calibration................................................................................................. 11
4.2.4 Save Calibration Data.......................................................................................................... 14
4.3 DP Transducer Standardization ................................................................................. 15
4.4 Flow Check ................................................................................................................. 24
4.4.1 Check Aeration Flow .......................................................................................................... 24
4.4.2 Check Coolant Flow ............................................................................................................ 24
4.4.3 Check Fuel Flow .................................................................................................................. 24
ALCOR JFTOT III Users Manual Section 4: Calibration
SECTION 4:
CALIBRATION
4.1 OVERVIEW
This section of the User’s Manual provides procedures to calibrate or check the
operation of major components used in the JFTOT 230 Mark III Jet Fuel Thermal
Oxidation Tester (JFTOT III). These calibration or validation procedures should be
performed on a regular schedule.
NOTE: Calibration schedules and logs should be provided by the user to record the
calibrations performed on the JFTOT III. All calibrations required for the
JFTOT III must be performed only by a qualified personnel.
NOTE: Adjustments are sometimes required to ensure that proper values are being
maintained. Refer to “JFTOT III Adjustments” in Section 5.4.
NOTE: The JFTOT III should be powered on for at least 20 minutes before
performing any calibration steps.

Revision B Page 4-1
4.2 CALIBRATION PROCEDURES

This section of the User’s Manual provides procedures to calibrate three major
components in the JFTOT 230 Mark III Jet Fuel Thermal Oxidation Tester
(JFTOT III). These calibration procedures should be performed on the following
components at least once every six months or when necessary to ensure valid output
data.
• Heater Tube Thermocouple and associated components
• System Pressure Transducer and associated components
• DP Transducer and associated components.
The AUTOCAL mode is used to perform standard calibration for all three major
components. Examples of displays are shown to illustrate the calibration procedure.
The dates, times, temperatures, and pressure readings are provided only as examples,
and will vary to reflect the actual condition of the equipment.
Perform the following calibration procedures in the order listed, then save the
calibration data.
4.2.1 TEMPERATURE CALIBRATION

The following procedure is used to calibrate the heater tube thermocouple
temperature system.
WARNING: This procedure involves heating lead to over 327°C to a melted state. A risk
of severe burns exists unless extreme caution is used when handling the
heated lead standard.
Calibration of the temperature controller and heater tube thermocouple requires the
following low and high temperature standards:
• Low Temperature standard: Freezing point of pure water (ice bath at 0°C)
• High Temperature standard: Eutectic of pure lead (Freezing point at 327.5°C)
The heater-tube thermocouple is calibrated for both high and low temperature
standards. The JFTOT III measures and records the temperature detected for each
standard. Corrections are made based on the new readings and then temperatures are
calculated to display the calibrated temperatures.
1. Obtain the necessary equipment for both low (ice bath) and high (Lead Auto-
Cal Tube AL-35387) calibrations.
2. Prepare an ice bath by filling a Styrofoam cup with clean ice and then adding
pure water. This will be the low temperature reference source.
3. From the Main Screen (Figure 4-1), press or click the AUTO-CAL button to
display the JFTOT III Auto-Calibration Menu.

Page 4-2 Revision B
FIGURE 4-1
MAIN SCREEN – AUTO-CAL BUTTON
4. From the Auto-Calibration Menu (Figure 4-2), press or click the CALIBRATE
TUBE THERMOCOUPLE button to display the Calibrate Low-Temperature
screen shown in Figure 4-4.
FIGURE 4-2
AUTO-CALIBRATION MENU
5. Follow the instructions in the message panel at the top of the Calibrate Low-
Temperature screen (Figure 4-3) to calibrate the auto-cal low-temperature
reference point.

Revision B Page 4-3
FIGURE 4-3
CALIBRATE LOW-TEMPERATURE SCREEN
6. Insert the thermocouple into the 0°C ice bath as shown in Figure 4-4.
FIGURE 4-4
ICE BATH LOW TEMPERATURE REFERENCE
Thermocouple
Ice and Pure Water

Low-Temperature (0°C)
Reference
7. With the thermocouple in the ice bath, adjust the min deg C reading to obtain a
“Tube Temp” reading of 0.1° C.
8. Click OK to continue. The High-Temperature calibration message appears as

Page 4-4 Revision B
FIGURE 4-5
CALIBRATE HIGH-TEMPERATURE INSTALL LEAD SCREEN
9. Install the lead auto-cal assembly in the bus bars. Ensure the top of the autocal
assembly is flush with the top of the upper bus bar as shown in Figure 4-6A.
Tighten the end caps to insure good connection.
10. Insert the thermocouple as shown in Figure 4-6B. Ensure the thermocouple is
in contact with the lead material inside the well as shown in Figure 4-6C.
FIGURE 4-6
LEAD AUTOCAL ASSEMBLY
A B C
Thermocouple
Tip
Top of AutoCal Lead

Assembly
Lead Autocal
Top of Upper
Assembly Well
Bus-Bar
Assembly

Revision B Page 4-5
11. Follow the instructions in the message panel and press or click OK to
continue. The lead standard heating process begins and the message in Figure
4-7 is displayed.
FIGURE 4-7
HEATING SCREEN
12. The JFTOT will heat the lead to 350°C. Make sure the thermocouple tip
maintains contact with the lead during the heating process.
13. Once the temperature reaches 350°C, you will be instructed to insert the
thermocouple all of the way into the auto-cal tube as shown in Figure 4-8.
Make sure the thermocouple is inserted all the way down and the tip is
centered in the lead.
FIGURE 4-8
INSERT THERMOCOUPLE SCREEN

Page 4-6 Revision B
14. When you have completed the instructions, press or click the OK button. The
heating will stop and the JFTOT III will search for the eutectic (refreezing
point). The lead standard cooling process is displayed as a decreasing
temperature curve with a flat plane where the eutectic occurs as shown in
Figure 4-9. The JFTOT III will determine if the eutectic was found and if it was
within the tolerances allowed.
FIGURE 4-9
CALIBRATE TUBE THERMOCOUPLE SCREEN - EUTECTIC SEARCH
Eutectic (327.5°C)
15. When the lead temperature cools to 300°C, the JFTOT III will reheat the lead
to 350°C and prompt you to remove the thermocouple from the lead as shown
in Figure 4-10.
16. Raise the thermocouple tip to make it accessible and remove all of the residual
traces of silicone and lead by wiping the tip with paper tissue. Remove the
thermocouple completely from the auto-cal tube. Inspect the tip closely for
cleanliness. The JFTOT III will turn the heater off automatically when the
thermocouple is removed from the melted lead.

Revision B Page 4-7
FIGURE 4-10
CALIBRATE TUBE THERMOCOUPLE SCREEN – REMOVE THERMOCOUPLE
17. A dialog box will appear (Figure 4-11) that will inform you whether the
calibration was successful or not and will give you the option to repeat the
heater-tube thermocouple calibration or EXIT. If successful, continue with
step 19, otherwise continue with step 18.
FIGURE 4-11
HEATER-TUBE THERMOCOUPLE CALIBRATION COMPLETE DIALOG BOX
18. If a lead freezing point temperature (eutectic) was NOT detected then press
REPEAT to attempt detection of the freezing point again. If you press EXIT,
do not save the calibration data at the end of the calibration procedure. Failure
to detect a good calibration temperature could be caused by several factors
listed below:
• Operator is not following the procedures correctly. Carefully read the
instructions and repeat the procedure (i.e. make sure thermocouple tip
is centered in lead).
• Lead contaminated. To replace, see Section 5.2.1 Maintenance and
Service. Repeat procedure.
• Thermocouple is defective. Replace and repeat AUTOCAL procedure.

Page 4-8 Revision B
• Computer or amplifiers are malfunctioning. See 5.3.6.5 for information

on the Interface PCB or contact your authorized PAC service
representative.
19. If a lead freezing point temperature (eutectic) was detected then press EXIT to
return to the JFTOT III Auto-Calibration Menu.
20. When cool, remove the lead auto-cal calibrator from the bus bars. Then
continue with procedure 4.2.2 System Pressure Transducer Calibration.
4.2.2 SYSTEM PRESSURE TRANSDUCER CALIBRATION
Perform the following steps to calibrate the JFTOT III system pressure transducer.
1. From the Auto-Calibration Menu (Figure 4-12), press or click the CALIBRATE
SYSTEM PRESSURE button. The Calibrate System Pressure screen
(Figure 4-13) is displayed.
FIGURE 4-12
AUTO-CALIBRATION MENU – CAL SYSTEM PRESSURE SELECT
2. If the “Sys Pressure” readout is not displaying zero (+0/–0), press or click the
control at the left of the “min psi” readout (Figure 4-13) until the “Sys
Pressure” reading displays zero (+0/–0).

Revision B Page 4-9
FIGURE 4-13
CALIBRATE SYSTEM PRESSURE SCREEN
3. Obtain the calibration certificate (Figure 4-14) for the transducer being
calibrated and note the calibration factor value on the certificate. Ensure the
serial number on the certificate is the same as the serial number on the
transducer.
FIGURE 4-14
CALIBRATION CERTIFICATE (EXAMPLE)
Transducer
Serial Number
Calibration Factor
NOTE: The pressure transducer certification lists the milivolts as a Calibration

Factor in mV/Volt. Since the excitation voltage is 10 Volts, the number to
enter as the CAL MV in the Calibrate Differential Pressure screen will be 10
times the Calibration Factor on the Certificate.

4. Multiply the Cal Factor on the certificate by 10 Volts. For example, 2.002910
mV/V x 10 V = 20.03 Cal mV.
5. Press the control at the left of the “Sys Pressure Cal millivolts” (Figure 4-15)
reading to change the displayed number to the cal-millivolts value determined
in Step 4.
FIGURE 4-15
CALIBRATE SYSTEM – CAL MV SCREEN
6. Press or click the OK button to return to the JFTOT III Auto-Calibration.

Then continue with procedure 4.2.3 DP Transducer Calibration.
4.2.3 DP TRANSDUCER CALIBRATION

Perform the following steps to calibrate the JFTOT III Differential pressure (DP)
transducer.
NOTE: For best results ensure the lines normally connected between the test section
and bulkhead fittings are removed.
1. From the Auto-Cal screen (Figure 4-16), press or click the CALIBRATE
DIFFERENTIAL PRESSURE button. The Calibrate Differential Pressure screen
(Figure 4-17) is displayed.

FIGURE 4-16
AUTO-CAL SCREEN
2. If the “Diff Pressure” readout is not displaying zero (+0/–0), press or click the
control at the left of the “min mmhg” readout (Figure 4-17) until the Diff Press
reading displays zero (+0/–0).
FIGURE 4-17
CALIBRATE DIFFERENTIAL PRESSURE SCREEN
3. Obtain the calibration certificate (Figure 4-18) for the transducer being
calibrated and note the number for the calibration factor on the certificate.
Ensure the serial number on the certificate is the same as the serial number on
the transducer.

FIGURE 4-18
CALIBRATION CERTIFICATE (EXAMPLE)
Transducer
Serial Number Calibration Factor
NOTE: The pressure transducer certification lists the milivolts as a Calibration

Factor in mV/Volt. Since the excitation voltage is 10 Volts, the number to
enter as the CAL MV in the Calibrate Differential Pressure screen will be 10
times the Calibration Factor on the Certificate.
4. Multiply the Cal Factor on the certificate by 10 Volts. For example, 2.002910
mV/V x 10 V = 20.03 Cal mV.
5. Press the control at the left of the “Diff Pressure Cal millivolts” reading
(Figure 4-19) to change the displayed number to the cal-millivolts value
determined in Step 4.
FIGURE 4-19
CALIBRATE DIFFERENTIAL PRESSURE SCREEN

6. Press or click the OK button to return to the JFTOT Auto-Calibration Menu.

Then continue with procedure 4.2.4 Save Calibration Data.
4.2.4 SAVE CALIBRATION DATA

1. When all calibrations are complete, press or click the EXIT button on the
JFTOT III Auto-Calibration Menu to return to the JFTOT III Main program
screen. A small window (Figure 4-20) will appear and prompt you to replace
the existing file “C:\Jftot\cal.txt”.
2. If the calibration completed successfully press or click the REPLACE button. If
the calibration was not successful then press or click the CANCEL button
(determine the reason for the failure and recalibrate).
FIGURE 4-20
CALIBRATE TUBE THERMOCOUPLE SCREEN – REPLACE FILE OPTION
3. The calibration procedure is now complete and the calibration data has been
saved in the computer.

4.3 DP TRANSDUCER STANDARDIZATION

The standardization of the differential pressure (DP) transducer is accomplished by
applying a defined pressure that is created by a fuel of known density at room
temperature. The term “standardization” is used here instead of calibration to
differentiate between the work that can be done to assure the transducer is operating
properly (standardizing) and the absolute value that only can be verified with the
Bureau of Standards procedures and specially calibrated instruments (calibrating).
For our purposes, standardizing is sufficiently accurate to determine if there is a
problem with a pressure transducer.
Basically, pressure transducer standardization involves removing the air from the
lines throughout the system, zeroing the transducer, applying a measured height of
fuel to the transducer and then calculating the theoretical differential pressure. This
value is compared to the value displayed on the screen. The difference, if any, should
fall within a small range of acceptable error. Values beyond this minimum error are
suspect, and the test should be performed again to confirm the error. If confirmed, a
persistent error suggests that a transducer may have drifted in accuracy; it can then
be calibrated by existing standard techniques.
The transducer is factory calibrated to give a pressure reading that is equivalent to
that which would result from using the original fuel/mercury manometer. When a
static check is made to confirm that the transducer is functioning properly, the
reading includes the offset tare for the flow compensation and the bias due to the
basis being a mercury-kerosene manometer. The readings, therefore, are consistent
with all JFTOT analyzers (ASTM D3241).
The following procedure can be used to ensure that the Differential Pressure
Transducer (DPT) system is within the operational limits required for the test.
Differential Pressure Transducer systems failing these criteria should be serviced by
a qualified technician.
1. The standardization technique uses a fuel of known density. Determine the
density by weighing to four decimals a 10.0 ml pipetted volume of the test fuel.
Typically, one milliliter of fuel weighs approximately 0.8 gms. When 10 ml of
sample fuel is used for the test, the sample weight will be approximately 8.0
gms. The fuel density can be used to determine a calculated value for fuel at a
given height from a zero point for comparison to the reading displayed on the
JFTOT III screen.

NOTE: If the exact weight of the fuel being used must be determined, the container
must be weighed before the fuel is added and then subtracted from the total
weight of the fuel and the container.
2. The theoretical DP for the transducer can be determined from the following
(Fuel Density in gms/ml) x (height from zero reference in millimeters)

DP =
(Hg Density) x (100% -% Bias)
For Example:
Fuel Density =0.800 gms/ml
Height from 0 = 400 mm
Hg Density = 13.53 gms/ml
JFTOT Bias = 6%
(0.800 gms/ml) x (400mm)

DP = = 25.16 mmHg
(13.53 gms/ml) x (0.94)
equation:
3. Fill the test fuel bottle with the test fuel as shown in Figure 4-21. The bottle
cap has a hole to provide an open-to-atmosphere condition while minimizing
spillage. The free end of the line can be inserted into the hole to prevent
draining when not in use.
FIGURE 4-21
TEST-FUEL BOTTLE
NOTE: The DP Transducer Calibration procedure in Section 4.2.3 must be

performed prior to performing this standardization procedure.
performing the DP standardization steps

4. Place the fuel output container under the fuel output tubes as shown in
Figure 4-22.
FIGURE 4-22
FUEL OUTPUT CONTAINER
5. If installed, remove the heater tube test section from the bus bars as described
in Section 3.5 “Disassembly”.
6. From the Main Menu (Figure 4-23), press or click the MAINT button to display
the Maintenance screen as shown in Figure 4-24.
FIGURE 4-23
MAIN SCREEN MAINTENANCE BUTTON
7. The temperature and pressure values are shown in the temperature and
pressure gauges (Figure 4-24) on the right of the screen.

FIGURE 4-24
MAINTENANCE SCREEN DP BYPASS BUTTON
8. Press DP BYPASS button to turn off (CLOSE) the bypass valve (ON indicator
changes to OFF). Each time DP BYPASS button is pressed, the bypass valve
will change position (open and close) and the green indicator will light (ON)
and darken (OFF) respectively.
9. Allow the line from the leveling bottle to fill with the fuel, and then attach the
line fitting to the DP – Port while minimizing air left in line.
10. Press the DP – VENT button on the Maintenance screen (Figure 4-24) to turn
on (open) the DP – purge valve.
CAUTION: The test must be run with no air in the lines (fuel only) in order to have
meaningful results. Ensure all air is purged from the system before taking
readings.
11. Raise the bottle over 400 mm above the port as shown in Figure 4-25. The
atmospheric pressure on the fuel in the bottle will push fuel, and any air,
through the system and out the drip tube.

FIGURE 4-25
DP – TRANSDUCER PURGE
Calibration Fuel
Sample
Fuel Output
Line Drip Tube
DP – Port
12. Hold the bottle up for approximately one minute. Transfer at least 50
milliliters of fuel. Any air in the system will flow out slowly and can be seen as
irregular drips from the fuel-out drip tube.
13. When air bubbles no longer emerge from the fuel output drip tube, press the
DP– VENT button on the Maintenance screen to turn off (close) the DP–
purge valve.
NOTE: To keep air from the line, do not place the bottle below the DP– fitting.
14. Lower bottle until the level of the fuel is at the same level as the DP–
Transducer Port as shown in Figure 4-26.

FIGURE 4-26
TEST FUEL BOTTLE LEVEL AT – DP PORT
DP – Port Sample Fuel Level

(0 mmHg position)
DP + Port
15. Remove the fitting from the DP – port and reattach to the DP+ Transducer
port. Do this quickly because fuel will drip from the open line fitting.
16. Press the DP +VENT button on the Maintenance screen (Figure 4-24) to turn
on (open) the DP+ purge valve.
17. Raise the bottle and again allow fuel to flow from the output tube bringing any
air that is in the system with it. Hold the bottle up for about a minute.
FIGURE 4-27
+ DP TRANSDUCER PURGE
Fuel Sample
DP + Transducer Port

18. Transfer at least 50 ml of fuel. Any air in the system will flow out slowly and
can be seen as irregular drips from the output tube. Make certain the level of
the test fuel in the bottle stays above the fitting on the bottom of the bottle.
19. When air bubbles no longer emerge from the fuel output drip tube, press the
DP + VENT button to turn off (close) the DP+ purge valve.
20. Lower the bottle so that the level of the fuel is level with the middle of the DP-
Port as shown in Figure 4-28.
FIGURE 4-28
TEST FUEL BOTTLE LEVEL AT - DP PORT
DP Transducer
Port (–) Sample Fuel Level
(0 mmHg)
DP +
Transducer
Port
21. Make a note of the reading displayed on the Maintenance screen (Figure 4-29)
for the Diff Press including its sign, if any. The reading should be
approximately 0.0 mmHg.
FIGURE 4-29
ZERO DP READING
0 mmHg Diff Press

22. Measure a point on the JFTOT III front panel that is 400mm (15.75”) above
the center of the – DP transducer port and mark the point with a pencil.
23. With the fuel line from the test fuel bottle connected to the +DP transducer
port, raise the bottle so the fuel level is even with the 400 mm point as shown
in Figure 4-30. This will cause the DP reading to increase since pressure has
been added to the positive side of the DP Transducer.
FIGURE 4-30
DP+ PRESSURE APPLICATION
Fuel Sample
Level
400 mm (15.75”)
(25 mm hg)
DP - Transducer
Port
24. With the fuel level held at the 400mm point, make a note of the DP reading on
the screen including its sign, if any. The reading will be approximately 25
mmHg as shown in Figure 4-31.
FIGURE 4-31
+ DP READING
Test Fuel
400mm Sample Level
(400mm)
Diff Pres
Reading
(25.0mmhg)
To -DP
Transducer
Input Port

25. Lower the test fuel bottle to the + DP port (Figure 4-32) and remove the test
bottle fuel line from the +DP transducer port. Place the end of the line in the
bottle cap to prevent draining the fuel out of the bottle.
FIGURE 4-32
TEST FUEL BOTTLE REMOVAL
DP Transducer
Input Port (–)
DP Transducer Sample Fuel Level

Input Port (+)
26. Calculate the Displayed DP Value from the two readings:

Displayed DP = (Value at 400mm) – (Value at 0mm)
27. Compare the displayed DP value with the theoretical DP value. The displayed
DP value should be within 5% of the theoretical DP value.
28. The DP Transducer standardization is complete.

4.4 FLOW CHECK

The following procedures are used to calibrate the aeration system and coolant
system flow rates.
4.4.1 CHECK AERATION FLOW

Check the aeration flowmeter at least once every six months as described in the
following steps.
1. From the Maintenance Menu press or click the Aeration Button to turn on the
air pump. Verify that the aeration flow can be adjusted to maintain the ball in
the center of the green range. When finished, press or click the Aeration
button to turn off the air pump.
2. If proper adjustment can not be obtained, check tubing, filter/dryer, and

aeration tube for obstructions. If necessary, have a qualified technician check
the air pump for proper operation.
4.4.2 CHECK COOLANT FLOW

Check the coolant flowmeter at least once every six months as described in the
following steps.
1. From the Maintenance Menu press or click the Bus Heater Button to turn on
the coolant pump.
2. Open the coolant flowmeter adjustment knob full counter-clockwise (CCW).

The ball should float about halfway between the green range and the top of the
flowmeter. If the ball floats to the top of the flowmeter, then the check valve is
either plugged, stuck or installed backwards. Refer to “Check Valve
Replacement” in section 5, Subsection 5.3.3.1.
3. Verify that the coolant flow can be adjusted to maintain the ball in the center
of the green range. When finished, press or click the Aeration button to turn
off the coolant pump.
4. If proper adjustment cannot be obtained, check the coolant container for
proper level (half full); check the tubing, bus bar and radiator for obstructions;
check the water pump for proper operation.
4.4.3 CHECK FUEL FLOW

The calibration of the flow rate is internal and not accessible to the user. A detailed
discussion of the flow system is given in Section 5.3.5 “Sample Delivery System” of
the Service part of the manual. The following procedure can be used to ensure that
the flow rate is within the limits required for the test.
Check the fuel flow periodically as described in the following steps.

1. During a D3241 or CUSTOM test, place a clean beaker under the drip tube
when the heater turns on. Remove the beaker when the heater turns off.
Record the elapsed time the heater is on.
2. Pour the spent fuel into a clean graduated cylinder and measure the volume to
the nearest millimeter.
3. Calculate the flow rate by dividing the fuel volume by the elapsed time reading
(Flow Rate =Fuel Volume/Test Time) to arrive at the calculated flow rate in
ml/min. Flow rate should be very close to the specified rate for the test (3.0
mL/min for D3241).
Flow Rate errors in excess of 10% invalidate the test; contact PAC Technical Service
with details. The JFTOT III should maintain the flow rate within 0.1 mL/min of the
specified flow rate.
Systems with flow rates failing this test should be serviced by a qualified technician.

JFTOT 230
MARK III
USER’S MANUAL
SECTION 5: MAINTENANCE AND SERVICE
PN: AL-59322
Revision B


05.18.06
REVISION HISTORY
SECTION 5: MAINTENANCE AND SERVICE...................................................................... 1
5.1 Component Locations.................................................................................................... 1
5.1.1 Internal JFTOT Components ................................................................................................1
5.1.2 Control Components ..............................................................................................................2
5.1.3 Aeration System .....................................................................................................................3
5.1.4 Sample Delivery System.........................................................................................................4
5.1.5 Coolant System .......................................................................................................................7
5.1.6 Heater Tube Heat Control .....................................................................................................8
5.1.7 Temperature Controls ............................................................................................................9
5.1.8 Power Distribution Components........................................................................................ 10
5.1.9 Safety Components.............................................................................................................. 11
5.1.10 Back Panel Components...................................................................................................... 11
5.2 Maintenance................................................................................................................ 13
5.2.1 Lead Standard Replacement ............................................................................................... 14
5.2.2 Aeration Dryer Replacement.............................................................................................. 16
5.2.3 Cleaning Bus-Bar Contacts.................................................................................................. 17
5.2.4 Cleaning the Display, Keypad and Printer......................................................................... 18
5.2.5 Replacing the Sample-IN Filter and Aeration Diffuser .................................................... 19
5.2.6 Replacing the Charcoal Filter ............................................................................................. 19
5.3 Service......................................................................................................................... 20
5.3.1 Fuel Sample System Components Replacement................................................................ 20
5.3.1.1 Bus-Bar Thermocouple Replacement................................................................................. 22
5.3.1.2 Bus-Bar Assembly and Jet Tube Replacement .................................................................. 22
5.3.1.3 Sample Drive Pump Replacement ...................................................................................... 24
5.3.1.4 Valve Assembly Replacement............................................................................................. 27
5.3.1.5 Solenoid-Controlled Valve Assembly Replacement .......................................................... 28
5.3.1.6 Differential Pressure (DP) Transducer ............................................................................. 30
5.3.1.7 System Pressure Transducer Replacement........................................................................ 31
5.3.1.8 Back Pressure Regulator Replacement .............................................................................. 32
5.3.2 Fuel Aeration System Components.................................................................................... 33
5.3.2.1 Air Pump.............................................................................................................................. 33
5.3.2.2 Dryer Replacement.............................................................................................................. 34
5.3.2.3 Relative Humidity (RH) Sensor Replacement .................................................................. 34
5.3.2.4 Aeration Flow Meter Replacement .................................................................................... 35
5.3.3 Cooling System Components .............................................................................................. 35
5.3.3.1 Coolant Pump Assembly and Check Valve Replacement ................................................. 36
5.3.3.2 Flow Meter Replacement .................................................................................................... 38
5.3.3.3 Radiator and Fan Replacement .......................................................................................... 39
5.3.3.4 Coolant Container Replacement......................................................................................... 40
5.3.3.5 Coolant Jets and Bus Bars Replacement ............................................................................ 41
5.3.3.6 Coolant System Jet Tube Replacement .............................................................................. 42
5.3.4 Tubing and Fittings ............................................................................................................. 43
5.3.4.1 Metal, Nylon or Teflon Tubing and Swagelok Fittings .................................................... 43
5.3.4.2 Flexible Tygon Tubing and Swagelok or Barbed Fittings................................................. 43
5.3.5 Power Supply and Heater Supply System.......................................................................... 44
5.3.5.1 Power Entry Module Replacement .................................................................................... 44
5.3.5.2 Step-Down Transformer Replacement .............................................................................. 45
5.3.5.3 Power Distribution PCB and SSR Module Replacement.................................................. 46
5.3.5.4 Power Distribution PCB (AL-54743) LED Description ................................................... 48
5.3.5.5 Power Distribution PCB Cable Connections ..................................................................... 48
5.3.5.6 24-VDC Power Supply Replacement.................................................................................. 50
5.3.5.7 Heat Control Assembly Replacement ................................................................................ 51
5.3.5.8 SCR Heater Control Module Replacement ........................................................................ 52
5.3.5.9 Low-Voltage Transformer Replacement............................................................................ 52
5.3.5.10 RMS Current Transformer Replacement .......................................................................... 53
5.3.6 Control System Components .............................................................................................. 54
5.3.6.1 JFTOT III Embedded Computer Replacement .................................................................. 54
5.3.6.2 Touchscreen Alignment...................................................................................................... 56
5.3.6.3 Data Acquisition (DAQ) PCB Installation ........................................................................ 60
5.3.6.4 6024E DAQ PCI Board Configuration............................................................................... 65
5.3.6.5 Computer (PC) Interface PCB (AL-54741)........................................................................ 67
5.3.7 Pressure Transducer Voltage Checks................................................................................. 76
5.4 JFTOT III Adjustments............................................................................................... 79
5.4.1 Adjusting System Pressure (Back Pressure Regulator) .................................................... 79
5.4.2 Priming the Drive Pump ..................................................................................................... 80
5.4.3 Adjusting the SCR ............................................................................................................... 83
5.4.4 Adjusting the 5-VDC RH Reference Voltage..................................................................... 86
5.4.5 Power Entry Module Fuse Configuration.......................................................................... 87
5.4.5.1 Power Entry Fuse Reconfiguration (115VAC to 230VAC) ............................................. 87
5.4.5.2 Power Entry Fuse Reconfiguration (230VAC to 115VAC) ............................................. 89
5.5 Software Installation .................................................................................................. 91
5.5.1 MS Windows XP Professional OS Installation.................................................................. 91
5.5.2 NI-DAQ Software Installation............................................................................................ 91
5.5.3 JFTOT III Application Software Installation .................................................................... 96
5.6 Error Messages.......................................................................................................... 102
5.7 TroubleShooting Guide ............................................................................................. 103
5.7.1 Electrical/Electronic Component Replacement .............................................................. 103
5.7.2 Troubleshooting Guide ..................................................................................................... 104
5.8 Spares, Accessories, Supplies, and Materials ........................................................... 106
5.9 Drawings ................................................................................................................... 111
ALCOR JFTOT III Users Manual Section 5: Maintenance and Service
SECTION 5:
MAINTENANCE AND SERVICE
5.1 COMPONENT LOCATIONS
The locations and descriptions of JFTOT 230 Mark III Jet Fuel Thermal Oxidation
Tester (JFTOT III) internal and external components are included in the following
subsections.
5.1.1 INTERNAL JFTOT COMPONENTS

The internal JFTOT system components are shown in Figures 5-1A – 5-1D.
FIGURE 5-1A & B
JFTOT III LEFT SIDE PANEL ACCESSED COMPONENTS
A B
PC Interface
PCB
Power
Distribution
PCB
RH Detector
Air Pump Charcoal Filter

(16991)
Backpressure
Regulator Differential Pressure
Transducer and Valve
24-VDC Power Assembly
Supply
Power Entry
Module Sample Drive
Pump

Revision B Page 5-1
FIGURE 5-1C & D

JFTOT III RIGHT SIDE PANEL ACCESSED COMPONENTS
C D
Vent Fan
Computer
Step Down
Transformer
(230VAC /115VAC)
Coolant Fluid
Container
Upper Bus Bar Coolant Fluid
Assembly Pump
RMS Current Low-Voltage

Sensor Transformer
Radiator &
Lower Bus Bar
Fan Assembly
Assy
SCR Heater
Controller
5.1.2 CONTROL COMPONENTS

JFTOT III functions are controlled by a standard MS Windows driven computer
housed inside an enclosure mounted behind the touch screen. Installed in the
computer enclosure is a DAQ ISA PCB assembly that serves as a translator between
the computer and the JFTOT III system. The DAQ PCB communicates with the PC
Interface PCB through a 50-pin cable. The PC Interface PCB connects computer
signals between the computer and devices such as control solenoids, thermocouples,
drive motors and heating devices.
The following assemblies are used to provide control for the JFTOT III.
• Embedded PC with front-panel mounted touch-screen LCD and Data
Acquisition (DAQ) PCB (Figure 5-2 A)
• PC Interface PCB (Figure 5-2 B). See “Computer (PC) Interface PCB
(AL-54741)” in Section 5.3.6.5 for detailed descriptions and replacement
procedures.

Page 5-2 Revision B
FIGURE 5-2
CONTROL COMPONENTS
A B
5.1.3 AERATION SYSTEM

A filtered air supply system provides dry, filtered air at 1.5 L/min for 6 min for
aerating the fuel sample. A silica gel filled container is used to dry and filter the air
before it enters the fuel. Replacement silica gel (indicating Dri-rite, p/n 71012) is
available when the color changes from blue to pink.
A humidity sensor monitors the air to ensure 20% RH is not exceeded.

Approximately 9.0 liters of air is passed through the fuel ensuring at least 97% of air
saturation of the fuel sample. The JFTOT III automatically turns the air pump off
after 6 minutes.
The components used in the aeration system shown in Figure 5-3A, B, C and D are
listed and described as follows:
• Air Pump: 24VDC air pump supplying air to the sample (Figure 5-3A)
• Humidity Sensor: computer input device (Figure 5-3A) used to sense the
moisture level in the air supply. The computer reads this value and determines
if the humidity level is over the maximum amount allowed (typically 20% RH)
• Dryer: container filled with moisture absorbing Dri-Rite desiccant and color
indicator chemical placed in the output line of the air pump (Figure 5-3B)
• Air Flowmeter: sight-glass and ball flow meter used to manually set the air
supply flow rate (Figure 5-3-C)
• Sparging Diffuser: diffusing element (P/N: AL-27096) and fitting (P/N: AL-
28432) for the air supply placed at the end of the air supply line in the sample-
in container (Figure 5-3D)

Revision B Page 5-3
FIGURE 5-3
AERATION SYSTEM COMPONENTS
A B C D
Humidity
Sensor
Aeration
Pump
Plastictight
Fitting
(Al-28432)
Aeration-Out
Diffuser
(AL-27096)
5.1.4 SAMPLE DELIVERY SYSTEM

Before pressurizing the system, the fuel system is bled of any air so the system is
liquid full when placed under pressure during a test.
A regulator at the outlet of the sample system maintains the pressure at a constant
level by allowing a constant “leak” flow rate through the system and out into the
sample-out container. The drops leaving the output tube can be timed to check the
flow rate. An absolute pressure transducer measures the fuel pressure in the overall
sample system. The transducer sends a signal to the controller to ensure the pressure
is maintained at 500 psig ± 10%.
From the pump outlet fitting, the fuel flows through a 0.45 micron membrane type
filter, and then to the lower (inlet) of the test section. The heater tube is connected
between two electrically powered bus bars and is electrically insulated from the test
section by means of a non-conductive ferrule/o-ring combination. The fuel rises
vertically in the annular space between the aluminum heater tube and the test
section. A low-voltage, high-current AC signal is passed through the heater tube to
produce resistance heating.
As the fuel exits the heater tube test section, it passes through a DP filter having an
element made from stainless steel cloth with a rated porosity of 17 microns.
A differential pressure transducer (DPT) is used to measure the differential pressure
across the test DP filter as the filter fouls with products from the fuel degradation.
The transducer is connected across the test filter as shown in Subsection 1-2
“Functional Block Diagram”.

Page 5-4 Revision B
The DPT output is controlled by two solenoid-controlled valves: the solenoid-

controlled positive (+) purge valve, and the solenoid-controlled negative (–) purge
valve. A solenoid-controlled bypass valve is across the DP filter and the input of the
DPT to allow fuel to be ported around the filter if the differential pressure is over a
set value (250 mmHg).
The bypass valve is operated automatically by the JFTOT III when the pressure
across the filter exceeds 250 mmHg allowing the test to continue to obtain heater
tube deposits for the full test period. The system-vent valve provides a means to vent
and eliminate any trapped fuel and air from the system when required. The safety-
vent valve is used as a backup valve for the system vent valve.
The fuel proceeds through the pressure regulator, then drips from a line into the
sample-out container. The drip rate allows visual monitoring of the flow rate. See
Subsection 1.2 “Functional Block Diagram”.
The front panel components (Figure 5-4) used in the sample delivery system are
listed and described as follows:
FIGURE 5-4
FRONT PANEL SAMPLE DELIVERY COMPONENTS
Sample Fuel
Coolant
OUT Container
Flow Meter
Sample Fuel Upper Bus-Bar

IN Container
Sample-IN DP Filter Assy

Filter Heater Tube Assy
Lower Bus-Bar
Sample Drive
Pump Pre Filter Assy
Pump Outlet fitting
• Sample-In and Sample-Out Containers: two 1000 ml, scaled, glass beakers
• Sample-In Filter: porous stone filter element placed on the sample-in tube
inside the sample-in container to filter fuel particles larger than 10mm
• Sample-Drive Pump: HPLC dual-piston chemical pump capable of
delivering continuous flow at approximately 500 psig
• Pre-filter: Inline filter placed at the output of the sample pump to trap
particles
• Bus-Bar Assemblies: used for mounting the heater tube. The bus bars
conduct high-current from a low-voltage source for heating the heater tube
• Heater Tube: hollow aluminum tube with smaller diameter center for
collecting oxidation from fuel sample on the external surface under closely
controlled temperature and flow rates

Revision B Page 5-5
• Differential Pressure (DP) Filter: filter for catching deposits not formed
on the heater tube. The system is set to bypass the DP filter at a pressure
differential greater than 250 mmHg.
The internal components (Figure 5-5) used in the sample delivery system are listed
and described as follows:
FIGURE 5-5
INTERNAL SAMPLE DELIVERY COMPONENTS
DP + Purge DP – Purge Solenoid-

Solenoid- Controlled Controlled Valve
Valve
Differential Pressure
Bypass Solenoid- Transducer
Controlled Valve
System Vent Solenoid-
Controlled Valve
System Pressure
Transducer Safety Vent Solenoid-
Controlled Valve
Back Pressure
Regulator Valve
• Bypass Solenoid Valve: solenoid controlled valve used to route the sample
around the DP filter when differential pressure exceed 250mmHg
• Differential Pressure (DP) Transducer: Computer input device used to
monitor system pressures on each side (+/ – ) of the DP filter
• +DP Purge Solenoid Valve: solenoid controlled valve connected to the
positive pressure (+) side of the DP transducer used to purge sample out of
the system to the sample out container
• – DP Purge Solenoid Valve: solenoid controlled valve connected to the
negative pressure (–) side of the DP transducer used to purge sample out of
the system to the sample-out container
• System Pressure Transducer: computer input device used to monitor
system pressure
• Back Pressure Regulator: spring-loaded pressure regulator manually set to
predetermined pressure (500 psi) by varying the orifice size at the output of
the sample flow system
• System Vent Solenoid Valve: solenoid-controlled valve used to vent the
system pressure into the sample out container when purging air from fuel
system or pressure exceeds maximum set limit
• Safety Vent Solenoid Valve: solenoid controlled valve used as a backup
valve for the system vent valve that will vent the system pressure into the
sample out container should the PC program crash or in the event of a power
failure

Page 5-6 Revision B
• Tubing and Fittings: high-pressure, stainless steel tubing and fittings used
to carry the sample to and from the heater tube and into the sample out
container
5.1.5 COOLANT SYSTEM

A self contained, closed loop cooling system provides cooling to the bus bar
assemblies. The JFTOT III has a rotometer type flow indicator to set the coolant flow
rate at 10 Gal/hr (38 ± 8 L/h). A coolant reservoir provides coolant to a pump. The
coolant is pumped through a fan-cooled radiator to remove heat from the fluid before
it reenters the coolant container. The coolant lines are electrically insulated from the
bus connectors by means of Teflon tubing. The coolant flows through the flow
control valve and the flow meter before returning to the coolant reservoir.
See flow diagrams in the Drawings section.
The components used in the coolant system shown in Figure 5-6 are listed and
described as follows:
FIGURE 5-6
COOLANT SYSTEM COMPONENTS
A B
Coolant Container
Coolant Flow Meter
Upper Bus Bar Coolant Pump
Upper Coolant
Jet Tube Check Valve
Lower Bus Bar

Fan
Lower Coolant Jet
Tube Radiator
• Coolant Flowmeter: Rotometer type flowmeter used to manually set the

coolant flow rate (Figure 5- 6A)
• Bus-Bar Assembly: two hollow cylindrical standoffs attached to a
mounting plate and installed in the JFTOT III front panel. The bus bars are
used to mount the heater tube test section and to provide connectivity for
heater cables and monitoring leads. The bus bars are internally cooled by
injected coolant from the circulating coolant system. (Figure 5- 6A)
• Cooling Jet Assembly: a smaller diameter internal tube that injects coolant
into the bus-bar assemblies. The coolant spray is forced back over the
injector and out the bus bar for circulation. (Figure 5- 6A)
• Coolant Container: plastic container used to hold coolant supply for the
sample cooling system (Figure 5- 6B)

Revision B Page 5-7
• Fan and Radiator Assembly: 115VAC fan mounted onto a air-cooled

radiator used to remove heat from the coolant returning from the heated bus-
bar assembly (Figure 5- 6B)
• Coolant Pump: 24VDC liquid pump used to circulate coolant through the
upper and lower heated bus bars (Figure 5- 6B)
5.1.6 HEATER TUBE HEAT CONTROL

The heater tube is heated by conduction of an electrical current of approximately 200
to 300 AC Amps at 0.3 to 0.5 VAC. The heater tube is clamped at each end into
corrosion resistant bus bar contacts.
The bus-bar temperature input signal to the JFTOT III computer is from a
thermocouple inserted through the top of the heater tube. The thermocouple is
placed in a permanent position inside the heater tube that allows the highest heater
tube temperature to be monitored.
The components used to heat the heater tube shown in Figure 5-7 are listed and
FIGURE 5-7
HEATER TUBE HEAT-CONTROL COMPONENTS
Current
Detection
Transformer Low-Voltage
(High Current)
Bus-Bar Transformer
Assemblies
SCR Heat
Controller
• SCR Heater Control: Silicone Controlled Rectifier (SCR) used to control

the power to the Low-Voltage Transformer
• Low-Voltage Transformer: Circular high-current (200-300 Amps AC),
low-voltage (0.3 to 0.5 VAC) transformer supplying AC power to the bus-bar
and heater tube from an electromagnetically coupled heater cable
• Secondary Power Cable: Terminated stranded wire cable looped three
times around the low-voltage transformer and connected from the lower bus
bar to the upper bus bar
• Current Detection Transformer: wire coil around one leg of the secondary
power cable to provide an RMS current meter input to the computer
• Voltage Leads: wires connected across the heater tube providing an RMS
voltage input to the computer for determining power used by the heater tube

Page 5-8 Revision B
5.1.7 TEMPERATURE CONTROLS

Sample temperature is measured by the computer to ensure the temperature is
within the limits specified by ASTM D3241 before allowing the test to begin. Heater
tube temperature inputs allow the computer to determine the amount of power to
apply to the heater tube in order to reach the temperature settings for the test. These
temperatures are also used by the system to diagnose problems due to variances from
expected values.
Calibration of the heater tube temperature indication system is accomplished by
utilizing the freezing point of 99% pure water (0°C) for a low temperature standard,
and pure melted lead (327.5°C) as the high-temperature standard. The low-
temperature standard is a container of pure ice and water. The high-temperature
standard consist of a special heater tube device which has at its middle section a
small well containing the pure lead into which the thermocouple to be tested is
immersed.
The heater tube thermocouple is introduced into the lead after raising the
temperature of the lead above the melting point. The cool-down temperature-time
characteristic is observed by the JFTOT III, which determines the temperature at
which the temperature pauses. Any difference between this reading and the true
freezing (solidified) temperature is the error in the temperature measurement
system. This error is recorded by the JFTOT and applied as a correction when
displaying subsequent heater tube temperatures
Components used to detect temperatures at three points in the JFTOT shown in
Figure 5-8 are listed and described as follows:
FIGURE 5-8
THERMOCOUPLES
A B
Sample-In
Thermocouple Bus-Bar
(AL-86301) Thermocouple
(AL-86302)
Heater Tube
Thermocouple
(AL-86303)
• Sample Temperature: Type-K thermocouple placed inside the sample in the

container to measure the sample temperature before it enters the system
(Figure 5-8A)
• Tube Temperature: Type-K thermocouple placed inside the heater tube to
measure the temperature at a predetermined position in the heater tube as an
input to the computer (Figure 5-8B)

Revision B Page 5-9
• Bus-Bar Temperature: Type-K thermocouple placed at the top of the bus-

bar to measure the temperature of the bus bar as an input to the computer
(Figure 5-8B)
5.1.8 POWER DISTRIBUTION COMPONENTS

When the power switch at the back of the JFTOT III is switched to the ON position,
the 115/230 VAC line power is applied to the computer. After the computer is
powered up and running, a watchdog timer relay provides 5 VDC from the PC to
turn on the base power relay.
The base power relay provides 115VAC from the step-down transformer to the
24VDC power supply, drive pump and vent fan. The heater SCR and coolant fan is
supplied 115VAC through the bus heater relay. All other components are powered
by commands from the computer through 24-VDC solid-state relays (SSR) or directly
from outputs from the amplifiers on the PC interface board.
Components used to supply electrical power to the JFTOT III shown in
Figure 5-9A-D are listed and described as follows:
FIGURE 5-9
POWER DISTRIBUTION COMPONENTS
A B
Power Entry Step-Down

Module Transformer
C D
Power
Distribution
PCB
24VDC Power
Supply
E
Blown Fuse (when lit)
Vent Fan Fuse ½ A (289036) Indicator LED (typical)
Fuel Pump Fuse (¾ A slo) (289034)
24 VDC PS Fuse (1½ A) (AL-29737)
Heater Power Fuse (4 A) (AL-29736)
PC Power Fuse (4 A) (AL-29736)

• Power Entry Module: Removable input power module that can be

reinstalled in the reverse position to allow input power to be either 115VAC
or 230VAC without reconfiguring the system. (Figure 5-9A)
• Step-Down Transformer: Input power transformer that converts 230 VAC
to 115VAC, which allows the input power to be either 115 or 230 VAC as
selected by the position of the power entry module(Figure 5-9B)
• 24 VDC Power Supply: 115VAC powered DC supply providing the system
power to the PC interface PCB, air pump, water pump and solenoid valves
(Figure 5-9C)
• Power Distribution PCB: PCB providing fused connectivity for 115 VAC
to the computer, heater, cooling fan, 24 VDC supply, sample drive pump, and
vent fan. (Figure 5-9D)
• Fuses: Fuses for the JFTOT III are located on the power distribution PCB
and are accessed at the back of the JFTOT III enclosure as shown in Figure
5-9E. When the LED for the fuse is on, the fuse is blown and will need
replacing. Using a flat-blade screwdriver, push in and turn the fuse holder
counter-clockwise to remove and clockwise to replace the fuses.
5.1.9 SAFETY COMPONENTS

Components used to provide safe conditions when using the JFTOT III are listed and
• Vent Fan: 115 VAC fan mounted in the upper-right from inside the corner
of the back panel removes vapors from the sample container area and test
area when the safety covers are closed. A charcoal filter is used to filter
hydrocarbons from the sample vapors being vented out of the enclosed
sample and test areas.
• Safety Covers: fire-proof hinged plastic covers that enclose the sample
container area and the sample test area to allow vapors to be removed and
prevent injury to the operator
• Limit Settings: displayed and/or verbal warnings given when critical limit
settings are exceeded. Automatic system venting and shutdown when
parameters such as flow, pressures and temperatures are over or under the
settings.
• Vent Valves and Safety Valves: Solenoid-controlled valves used to
automatically vent pressurized sample when necessary.
5.1.10 BACK PANEL COMPONENTS

Components located on the back panel (Figure 5-10) of the JFTOT III are listed and
• Vent Fan: See “Safety Components” in Subsection 5.1.9
• Coolant Radiator Fan: See “Coolant System” in Subsection 5.1.5
• Fuses: See “Power Distribution PCB” in Subsection 5.1.8
• Connectors: LAN, Keyboard, Mouse and Printer connectors
• Dryer: See “Aeration System” in Subsection 5.1.3

• Power Entry Module: See “Power Distribution” in Subsection 5.1.8

FIGURE 5-10
HEATER TUBE HEAT-CONTROL COMPONENTS
Vent Fan
Fuses (x5)
Dryer
Coolant
Radiator Fan Power Entry
Module
Connectors

5.2 MAINTENANCE
The Jet Fuel Thermal Oxidation Tester III (JFTOT III) has been designed to perform
standard and user-defined tests automatically after minor preparations have been
completed. The JFTOT III requires very little maintenance if installed correctly and
used properly as described in “Proper Use and Safety” at the front of this User’s
Manual. Routine maintenance requirements are listed in the following table.
NOTE: Maintenance schedules and logs should be provided by the user to record the
maintenance performed on the JFTOT III. All maintenance and service
required for the JFTOT III must be performed only by a qualified technician.
TABLE 5-1
MAINTENANCE INTERVALS
Maintenance Performed Interval

Preparation Procedures: (See Section 3.1.2 Preparation)
1. Replace Heater Tube
2. Replace DP Filter
3. Replace Pre-Filter Element
4. Clean Sample In and Sample Out Containers Before Each Test
5. Clean Pre-Filter housing and tubing
6. Clean Fuel-In and Fuel-Out lines
7. Clean Bus-Bar Contacts with tissue and solvent
(See Sec. 5.2.3)
Calibrate Heater Tube Temperature (See Sec. 4.2.1) Every 6 months (min)
Calibrate System Pressure Transducer (See Sec. 4.2.2) Every 6 months (min)
Calibrate DP Transducer (See Sec. 4.2.3) Every 6 months (min)
Standardize DP Transducer (See Sec. 4.3) Every 6 months (min)
Check Aeration Flow Meter (See Sec. 4.4.1) Every 6 months (min)
Check Coolant Flow meter (See Sec 4.4.2) Every 6 months (min)
Replace Lead Calibration Standard Material After 6 Auto Cal procedures, when
(See Sec. 5.2.1) contaminated or too low level
Inspect Aeration Dri-Rite® chemicals (See Sec. 5.2.2) Daily
®
Replace Aeration Dri-Rite chemicals (See Sec. 5.2.2) When color changes to pink
Clean Buss Bar Contacts with soft eraser (See Sec. 5.2.3) Yearly or after 50 Tests
Clean all JFTOT III external surfaces (See Sec 5.2.4) Every 6 months (min)
Replace Sample IN filter (Stone) (See Sec 5.2.5) Every 6 months (min)
Replace Sample OUT Filter (Stone) (See Sec 5.2.5) Every 6 months (min)
Replace Charcoal Filter (See Sec 5.2.6) Every 6 months (min)
NOTE: Refer to the following subsections for maintenance setup procedures.

5.2.1 LEAD STANDARD REPLACEMENT

The lead in the lead AutoCal Calibrator should be replaced whenever any of the
following occur:
• the lead has been used to perform six AutoCals,
• the lead is contaminated and reading seems erratic
• the quantity of the lead is below the minimum level
Perform the following steps to replace the lead standard material.
WARNING: This procedure involves heating lead to over 327°C to a melted state. A risk
of severe burns exists unless extreme caution is used when handling the
lead standard. Wear appropriate protection when performing this procedure.
1. Install the Lead AutoCal Calibrator inverted (open end down) between the
upper bus bar and the lower bus bar as shown in Figure 5-11. Use the steps in
Subsection 3.4.3 “Test Section Installation Procedures” as a guide in installing
the lead calibrator.
2. Place a paper tissue or cloth under the well to catch the old lead and a covering
over the end of the bus bar to shield the thermocouple orifice from the molten
lead.
FIGURE 5-11
LEAD STANDARD INSTALLATION FOR LEAD REMOVAL
Inverted Lead
Calibrator Well
Tissue or Cloth
3. From the Main Screen, press the MAINT button.
4. Press the % PWR control (Figure 5-12) on the Maintenance screen to display
55%.
5. Press the BUS HEATER button to turn on the bus heater to begin melting the
old lead.
6. After the old lead has dropped out of the calibrator, lightly tap the lead well
with a metal object to cause residual old lead to fall out.

7. Press the BUS HEATER button to turn off the bus heater.
FIGURE 5-12
MAINTENANCE SCREEN – SETUP DEFAULT TEST BUTTON
8. After the lead well has cooled, using the steps in Subsection 3.4.3 “Test
Section Installation Procedures” in reverse order as a guide, remove the lead
calibrator and reinstall it with the open-end up between the upper and lower
bus bars.
9. Press the BUS HEATER button on the Maintenance screen to begin heating the
lead calibrator.
FIGURE 5-13
THERMOCOUPLE REMOVAL
Lead Calibrator Well
10. After the well has heated to the lead melting point (350 deg C), refill the well
with new lead pellets (5.5 Gms or approximately 7 pellets).
11. Lightly tap the well with a metal object to remove air pockets that may form
inside the lead.
12 Press the BUS HEATER button on the Maintenance screen to turn the heater
off and stop heating the lead.

13. After the lead has cooled, remove the lead calibrator from the bus bars.
14. Press the MAINT button on the maintenance screen to return to the main
screen.
5.2.2 AERATION DRYER REPLACEMENT

The silica gel, located inside the aeration dryer, must be replaced when it is no longer
blue in color. The procedure for replacing the Dri-Rite silica gel is described below.
1. Loosen and remove the top dryer fitting (Figure 5-14A).
2. Remove the tubing from the bottom tapered fitting.
3. Pull out on the dryer (Figure 5-14B) to remove it from the spring clip mounts.
FIGURE 5-14
DRYER REMOVAL
A B
Top Dryer Fitting
Spring Clip Mounts
Bottom Dryer
Fitting
4. Loosen and remove the knurled end cap from the top of the dryer housing.
CAUTION: Do not discard the cotton filter located in the end caps. This cotton filter
ensures that the silica gel remains inside the tube.
FIGURE 5-15
DRYER DISASSEMBLY
Top End Cap
Gasket
Cotton Filter
Bottom End Cap

5. While holding the plastic cylinder in place, pour out and discard the old
Dri-Rite.
CAUTION: Do not use bead-type Dri-Rite when refilling the dryer. Use only granular
Dri-Rite.
6. Ensure the cotton filter is in place at the bottom end cap and then pour new
“blue” granular-type Dri-Rite into the plastic cylinder.
7. Reinstall the cotton filter and then hand-tighten the end caps onto the housing.
Ensure the gasket is in place at both ends of the tube.
8. Reinstall the dryer into the clip mounts and connect the bottom tubing and the
top fitting. Do NOT over tighten fittings during replacement. For new tubing
installation procedures, refer to Section 5.3.4. “Tubing and Fittings”.
5.2.3 CLEANING BUS-BAR CONTACTS

The contact area of the bus bars are gold plated and must be kept clean. During a
test, about 200 Amps AC passes through the contact area to heat the heater tube. In
order to prevent buildup of contact resistance, the bus-bar contacts should be cleaned
before beginning a test as described in the following procedure.
WARNING: A risk of severe burns exists unless power is removed and bus bars are
cooled prior to cleaning the bus bar contacts.
Before every test, the gold contact area of each bus bar and end cap should be
cleaned by performing the following procedure.
1. If the bus bars were recently heated, allow them to cool before continuing.
2. If heater tube assembly is installed, remove the bus-bar end caps and heater
tube assembly.
3. Use a tissue soaked with solvent to clean the gold contact area of each bus bar
and end cap as shown in Figure 5-16A.

FIGURE 5-16
CLEANING BUS BARS AND END CAPS
A B
Bus-Bar ID
Number
End Cap ID
Number
CAUTION: Before reinstalling the end caps onto the bus bars ensure the number on the
end cap matches the number on the bus bar.
4. If removed previously, reinstall the heater tube assembly and end caps.
Reinstall the end caps on the bus bar with matching ID numbers placed
together as shown in Figure 5-16B.
5. If over fifty tests have been run (or after every year) use an art gum type eraser
(very soft) and lightly rub the gold contact area to remove dirt and oxide.
CAUTION: DO NOT use hard erasers, emery paper or other abrasive material to clean
the contact area. Doing so will remove the gold plating.
5.2.4 CLEANING THE DISPLAY, KEYPAD AND PRINTER

Clean the JFTOT III cabinet, LCD display and accessories as described in the
following steps.
CAUTION: Never use solvents (including alcohol) to clean the LCD panel. Even vapors
from alcohol will damage the LCD panel. Use a clean cloth and mild cleaning
solution to remove finger prints etc from the panel surface.
CAUTION: Never use a sharp tool such as a pen or pencil to point to items on the
touchscreen. Doing so will permanently damage the screen. Use a stylus,
fingertip or a soft plastic tool to select items on the screen.
1. Clean the display once a month, or as needed, with a clean, dry, soft cloth and
a mild cleaning solution to remove fingerprints and dust from the display.
2. Use low pressure air (canned keyboard cleaner) and clean dust cloth to clean
the keyboard and printer.

3. Use a general purpose water-based cleaner and dry cloth to clean the JFTOT
cabinet.
5.2.5 REPLACING THE SAMPLE-IN FILTER AND AERATION DIFFUSER

The Sample-in filter (See Figure 5-4) and aeration diffuser (See Figure 5-3D)
elements can be replaced by simply removing the used elements from the line and
inserting a new element in the line.
If the Plastictight fitting (Figure 5-17) at the filter or diffuser is to be replaced,
perform the following procedure.
1. Slide the Plastictight fitting (AL-28432) on the Teflon tubing.
2. Position the fitting 1/8” from the end of the tubing as shown in Figure 5-17.
3. Thread the Plastictight fitting into the filter or diffuser and tighten to finger
tight. Do not use tools to tighten the fitting.
FIGURE 5-17
PLASTICTIGHT FITTING TUBE INSTALLATION
1/8”
Plastictight Male Nut

Teflon Tubing
5.2.6 REPLACING THE CHARCOAL FILTER

The charcoal filter (See Figure 5-1B) can be replaced by simply turning the tab to the
opened position, removing the used filter, installing the new filter and returning the
tab to the closed position.

5.3 SERVICE
This section of the JFTOT III User’s Manual contains problem analysis, repair and
part replacement information for the JFTOT III. This section is divided into
subsections that relate to each of the JFTOT III subsystems and components listed
below.
• Fuel Sample System
• Fuel Sample Aeration System
• Coolant System
• Heat and Power Supply System
• Control System
• Enclosures
A Troubleshooting Guide is included to help in diagnosing potential problems that
may occur while operating the JFTOT III. Listings of spare parts, accessories,
supplies and materials are also included along with a set of drawings and diagrams.
NOTE: All maintenance and service required for the JFTOT III must be performed
only by a qualified technician.
when setting up and performing the JFTOT III procedures. Ensure flames
and spark producing materials are kept well away from the JFTOT III test
area. Use standard safety procedures at all times.
WARNING: A severe electric shock hazard may exist when power is applied while
servicing internal components. Ensure that power lines are removed from
the power source before continuing.
5.3.1 FUEL SAMPLE SYSTEM COMPONENTS REPLACEMENT

The JFTOT III Fuel Sample System includes the following major front-panel
components listed below and shown in Figure 5-18.
• Containers (input and output)
• Fuel In and Out Lines
• Sample Drive Pump and Output Tubing
• Anti-Siphon Check Valve and Tubing
• Pre Filter and Fuel Input Line
• Upper and Lower Bus Bar Assemblies
• Heater Tube
• Test Section with Bypass Line
• DP Filter Assembly and Fuel Output Line

FIGURE 5-18
JFTOT III FRONT PANEL FUEL SAMPLE SYSTEM COMPONENTS
Sample Out and
Vent Lines
Sample In Line
and Filter
Sample Fuel In
Container
Upper Bus Bar
Sample Fuel
Out Container
DP Filter Assembly
Heater Tube Test Section
(Heater Tube Inside)
Sample Drive Lower Bus Bar
Pump Enclosure Pre-Filter Assembly and
Anti-Siphon Check Valve Input Tube
The JFTOT III Fuel Sample System also includes the following major internal
components listed below and shown in Figure 5-19.
• Bypass Solenoid-Controlled Valve Assembly
• Differential Pressure Transducer
• Purge Solenoid-Controlled Valves (+ and – )
• System Vent Solenoid-Controlled Valve
• Safety Vent Solenoid-Controlled Valve
• Back-Pressure Regulator
• Tubing and Fittings
FIGURE 5-19
INTERNAL FUEL SAMPLE SYSTEM COMPONENTS
DP Purge Solenoid- (–)

DP Vent Solenoid- (+)
Controlled Valve
Controlled Valve
(AL-93061)
(AL-93061)
Bypass Solenoid- Controlled

Valve (AL-93061)
System Vent Solenoid-
Controlled Valve
Transducer (AL-45042)
(AL-93061)
System Pressure
Transducer (AL-45043) Safety Vent Solenoid-
Controlled Valve
Back Pressure Regulator (AL-93062)
Valve (AL-61637)

5.3.1.1 Bus-Bar Thermocouple Replacement

Perform the following steps to replace the bus bar thermocouple.
1. If not already removed, perform the “Disassembly Procedures”
in Section 3.5 to remove the test section.
2. Loosen the collar set screw (Figure 5-20) on the side of the
thermocouple hold-down collar and then slide the collar off the
end of the upper bus bar. It may be necessary to loosen the
slide-stop setscrew.
FIGURE 5-20
UPPER BUS BAR ASSEMBLY
Bus-Bar
Thermocouple
Connection
Bus-Bar Thermocouple
(AL86302)
Thermocouple
Hold-Down Clamp
Bus-Bar Mounting
Thermocouple
Screws (x2)
Clamp Mount Block
Upper Bus-Bar
Thermocouple Assembly (AL-10774)
Wire Insertion
Thermocouple Hold-
Down Collar Screw
Thermocouple Hold-Down Collar
Test Section Fitting Slide Stop Setscrew
3. Remove the thermocouple wire from the orifice (Figure 5-20)

near the end of the upper bus bar and then unplug the bus-bar
thermocouple connector (Figure 5-20).
4. Use steps 1-3 in reverse order as a guide when installing a
replacement thermocouple.
5.3.1.2 Bus-Bar Assembly and Jet Tube Replacement

Over time the bus bar end and end caps will be worn due to
cleaning which will cause the resistance between the bus bar and
the heater tube to increase. When this happens or when the bus
bars are damaged, the entire bus bar assembly and end caps must be
replaced. Perform the following steps to replace the bus bar
assembly.
1. If not already removed, perform the “Disassembly Procedures”
in Section 3.5 to remove the test section.
2. Perform steps 2 and 3 in Subsection 5.3.1.1 to remove the bus-
bar thermocouple.
3. From inside the JFTOT III enclosure, drain all coolant from
the coolant system.

4. Remove all plastic coolant input and output coolant tubes

(Figure 5-21) form the lower and upper bus-bars.
5. Remove the upper and lower bus-bar mounting nuts from the
mounting plate voltage wires (Figure 5-21) and then remove
the two bus-bar mounting hex screws (Figure 5-20) from the
upper and lower front panels.
FIGURE 5-21
COOLANT LINES
Upper Bus-Bar Upper Bus-Bar and Voltage

Assembly (AL-10836) Wire Mounting Nut
Coolant Output Tube

Fitting (AL-28389) Upper Bus-Bar Coolant Jet-
Tube Fitting (AL-10831)
Upper Bus-Bar and
Power Cable Mount Nut Upper Bus-Bar Coolant Input
Tube Fitting (AL-28358)
Lower Power
Cable Mount Nut
Lower Bus-Bar
Assy (AL-10774) Lower Bus-Bar Coolant
Output Tube Fitting
Lower Voltage Wire (AL-28389)
Bus-Bar Mounting Nut
Lower Bus-Bar Coolant Coolant Input Tube
Jet-Tube (AL-10831) Fitting (AL-28358)
6. From inside the JFTOT III enclosure, slide the upper and
lower bus-bar assemblies (Figure 5-21) out of the bus-bar
mounting plate.
7. Remove the coolant jet tubes from the lower and upper bus-bar
assemblies (Figure 5-21).
8 Use the steps for removal in reverse order (7-1) as a guide for
replacing the bus bar assemblies. Ensure the flat surface of the
bus-bar is facing down. Install Teflon tape over pipe fitting
threads only. Do NOT over tighten fittings. For procedures on
installing new tubing, refer to Section 5.3.4. “Tubing and
Fittings”.
NOTE: When the tube is replaced, ensure the end of the coolant jet tube is ¼“away
from the bottom of the bus-bar coolant well. Refer to “Coolant System Jet
Tubes and Fittings” in subsections 5.3.3.6 for instructions on replacing the
coolant jet tube.

9. After installing the bus bars, the alignment bar (Figure 5-22)
must be used to align the bus bars in order to prevent any
bending of the heater tube when it is installed into the
bus bars.
FIGURE 5-22
BUS-BAR ALIGNMENT
Bus-Bar
Alignment
Bar (3/16´D)
5.3.1.3 Sample Drive Pump Replacement

Perform the following steps to remove and replace the sample fuel
drive pump (p/n 72020).
1. Switch off the power at the back of the JFTOT and unplug the
power connector.
2. If attached, slide the safety cover out of the hinges and place in
a safe location.
3. Loosen the thumbscrew on the cover plate covering the sample
drive pump and remove the cover plate to access the pump as
4. Ensure all sample fuel is drained from the pump input and
output lines (Figure 5-23)
5. Remove the two pump input lines from the piston head output
fittings by hand.
6. Use an open-end wrench to remove the output line anti-siphon
check-valve assembly from the pump output fitting and the
output line assembly bulkhead fitting.
7. Remove the two screws holding the door panel closure bracket
(Figure 5-23) to the pump enclosure and remove the bracket.

FIGURE 5-23
JFTOT III DRIVE PUMP ASSEMBLY
Door Panel Closure

Bracket Screws
Anti-Siphon Check
Valve (21084)
Pump Output
Line Fitting
Piston 1 Input Line
Output Line
Piston 2 Input Line Bulkhead Fitting
8. Remove the left-side panel and locate the drive pump assembly
and the valve assembly as shown in Figure 5-24.
FIGURE 5-24
DRIVE PUMP AND VALVE ASSEMBLIES
Valve Assembly
Drive Pump Assembly
9. Remove the power connector, the serial connector

(Figure 5-25) and the signal connector from the back of the
pump assembly.
FIGURE 5-25
JFTOT III DRIVE PUMP ASSEMBLY PROCEDURE
Power Cable
Connector Serial Cable
Connector
Signal Cable
Connector
10. Remove the right-side panel and locate the four mounting
screws holding the valve assembly mounting bracket to the
enclosure wall as shown in Figure 5-28 in Section 5.3.1.4.

11. Remove the lower two mounting screws and loosen the upper
two valve assembly mounting screws.
12. Have someone lift the valve assembly up as far as the valve
assembly mounting screw slots allow and then retighten the
upper two valve assembly mounting screws to hold the valve
assembly up off of the drive pump assembly.
13. From the front panel, lift the drive pump assembly up out of
the feet-locator holes and pull the pump assembly out the front
of the enclosure.
14. Use the removal steps in reverse order (13-1) as a guide for
replacing the pump assembly. Install Teflon tape over pipe
fitting threads only. Do NOT over tighten fittings. For new
tubing installation procedures, refer to Section 5.3.4. “Tubing
and Fittings”.
CAUTION: The new replacement drive pump assembly may contain a small filter on the
output connector. This filter must be removed before connecting the output
line to the new pump.
15. Before reinstalling the output lines in a new replacement

pump, perform the following steps to remove the internal filter
and seal from the output fitting of the new replacement pump
assembly.
15.1 Use a ½” socket wrench (Figure 5-26A) to remove the
output line fitting from the pump assembly. Some force
may be required to begin loosening the output fitting.
15.2 Using needle nose pliers at the filter base rotate (ccw) the
filter to remove the filter from the fitting as shown in
Figure 5-26B and C. Discard the filter and seal.
FIGURE 5-26
JFTOT III DRIVE PUMP FILTER REMOVAL PROCEDURE
A B C
Seal
Filter
15.3 Use a ½” socket wrench to reinstall the output fitting into

the pump. To ensure the high-pressure pump does not
leak, use some force to tighten the output fitting.

5.3.1.4 Valve Assembly Replacement

The valve assembly is composed of the following subassemblies:
• Back Pressure Regulator
• Differential Pressure Transducer
• System Pressure Transducer
• Bypass Solenoid-Controlled Valve
• System Vent Solenoid-Controlled Valve
• Safety Vent Solenoid-Controlled Valve
• DP + Purge Control Valve
• DP – Purge Control Valve
Perform the following steps to remove and replace the flow and
pressure regulation assembly.
1. Switch off the power at the back of the JFTOT III enclosure
and unplug the power connector.
2. Remove the left-side panel and locate the valve assembly
FIGURE 5-27
JFTOT III VALVE ASSEMBLY
DP Purge Solenoid- DP Vent Solenoid-

(–) Controlled (+) Controlled
Valve (AL-93061) Valve (AL-93061)
Vent Output
Line Fitting
Bypass Solenoid-
Controlled Valve
High DP In Line Fitting
(AL-93061)
Transducer (AL-45042) System Vent Solenoid-
Controlled Valve
(AL-93061)
System Pressure
Transducer
(AL-45043)
Safety Vent Solenoid-
Back Pressure Controlled Valve
Regulator Valve (AL-93062)
(AL-61637)
Sample Out
Line Fitting
Rubber Pad
3. Ensure all sample fuel is drained from all lines and then
disconnect the two input lines and the two output lines.

NOTE: Connectors P3 and P4 on the PC Interface PCB have a locking tab that must
be depressed while removing the connector.
4. At the PC Interface PCB, unplug the P2 connector (5 sets of 2

solenoid control wires), the P3 connector (system pressure
transducer wires) and Connector P4 (DP transducer wires).
See Wiring Tables in Section 5.3.6.5 “Computer (PC) Interface
PCB” for wire connections.
5. Remove the left side panel and remove the four mounting
screws (Figure 5-28) holding the valve assembly mounting
bracket to the enclosure wall.
FIGURE 5-28
VALVE ASSEMBLY MOUNTING SCREWS
Valve Assembly
Mounting Screws (x4)
6. Lift the entire assembly out of the enclosure.

7. Use the removal steps in reverse order (6-1) as a guide to
replace the valve assembly. . Install Teflon tape over pipe
fitting threads only.. Do NOT over tighten fittings. For
procedures on installing new tubing, refer to Section 5.3.4.
“Tubing and Fittings”.
5.3.1.5 Solenoid-Controlled Valve Assembly Replacement

Perform the following steps to remove and replace any of the
solenoid-controlled valve assemblies..
1. Perform the steps in procedure 5.3.1.4 for removing the entire
valve assembly.
2. Locate the solenoid-controlled valve assembly to be replaced as
in the example shown in Figure 5-29.

FIGURE 5-29
SOLENOID-CONTROLLED VALVE (EXAMPLE)
Solenoid-
Controlled
Valve
Assembly
Fuel Line
Fuel Line Fitting
Fitting
3. Remove the fuel lines (Figure 5-29) from the valve to

be removed.
4. Remove and retain the fuel line fittings for use on replacement
valve.
5. From the Wiring Tables in the “Computer (PC) Interface PCB”
subsection 5.3.6.5, determine the connection locations of the
wires going to the solenoid on the valve assembly to be
replaced.
6. Insert the push-wire connector tool into the rectangular hole
below the wire to be removed and press downward to open the
connector and release the wire as shown in Figure 5-30.
FIGURE 5-30
PUSH-WIRE CONNECTOR INSTALLATION
Push-Wire Connector
Push-Wire
Installation
Tool
7. Place the valve assembly on the side.
8. Locate and remove the two Philips-head screws (Figure 5-31)
holding the valve to the mounting plate and remove the valve
assembly.

FIGURE 5-31
SOLENOID-CONTROLLED VALVE REMOVAL (EXAMPLE)
Solenoid- Controlled
Valve Assembly
Mounting Screws (x2)
9. Use the removal steps in reverse order (8-1) as a guide to

replace the solenoid controlled valve assembly. . Install Teflon
tape over pipe fitting threads only. Do NOT over tighten
fittings. For procedures on installing new tubing, refer to
Section 5.3.4. “Tubing and Fittings”.
5.3.1.6 Differential Pressure (DP) Transducer

Perform the following steps to remove and replace the differential
pressure assembly.
power connector.
2. Remove the left and right side panels.
3. At the left-side of the JFTOT, locate the DP transducer
assembly as shown in Figure 5-32.
FIGURE 5-32
DP TRANSDUCER ASSEMBLY
DP Transducer
Assembly (AL-45042)
DP Transducer Hex Screw
nd
(2 hex screw in back)
Transducer Cable
4. Ensure all sample fuel is drained from all lines.

5 Disconnect the two input lines and the two output lines at the
DP Transducer Assembly.

6. Remove the P4 connector on the PC Interface board to

disconnect the signal cable going to the transducer.
7. Place a prop under the assembly to prevent the DP Transducer
assembly from falling during removal.
8. At the right-side of the JFTOT, remove the two hex
screws (Figure 5-33) holding the transducer bracket to the
enclosure wall.
FIGURE 5-33
DP TRANSDUCER ASSEMBLY BRACKET MOUNTING SCREWS
nd
2 DP Transducer
Bracket Mount Hex
Screw
DP Transducer Assembly
Bracket Mount Screws (x2)
9. At the left-side of the JFTOT III, carefully remove the DP

transducer and bracket.
valve.
11. Remove the two hex-screws (Figures 5-32 and 5-33) holding
the mount bracket to the DP Transducer.
12. To replace the transducer, use the removal steps in reverse
order (11-1) as a guide. Install Teflon tape over pipe fitting
threads only. Do NOT over tighten fittings. For procedures on
installing new tubing, refer to Section 5.3.4. “Tubing and
Fittings”.
5.3.1.7 System Pressure Transducer Replacement

Perform the following steps to remove and replace the system
pressure transducer.
power connector.
2. Remove the left side panel and locate the system pressure
transducer as shown in Figure 5-34.

FIGURE 5-34
SYSTEM PRESSURE TRANSDUCER REMOVAL
Input Line Fitting
Output Line Fitting
System Pressure
Transducer (AL-045043)
Cable
3. Remove the P3 connector on the PC interface board to

disconnect the signal cable going to the transducer.
4. Ensure all sample fuel is drained from all lines.
5. Remove the input and output lines from the transducer and
remove the transducer.
valve.
7. To replace the transducer, perform the removal steps in
reverse order (Steps 6-1) as a guide. Install Teflon tape over
pipe fitting threads only. Do NOT over tighten fittings. For
5.3.1.8 Back Pressure Regulator Replacement

power connector.
2. Remove the left side panel and locate the system pressure
transducer as shown in Figure 5-35.
FIGURE 5-35
BACK PRESSURE REGULATOR
Back-Pressure
Regulator (AL-61637)
Input Line Fitting

Mount Screw
Mount Screw
Output Line Fitting
Base Clamp Screw

3. Ensure all sample fuel is drained from all lines and then
remove the input and output lines (Figure 5-35) at the base of
the back-pressure regulator.
valve.
5. Remove the two mount screws (Figure 5-27) from the base
clamp.
6. Lift the regulator and clamp from the JFTOT III.
7. Loosen one of the clamp screws to remove the base clamp from
the regulator.
8. To replace the regulator, perform the removal steps in reverse
order (Steps 6-1) as a guide. Install Teflon tape over pipe
fitting threads only. Do NOT over tighten fittings. For
CAUTION: Before reinstallation, ensure the tubing is connected as indicated by the IN

and OUT fitting designations on the bottom of the regulator. Failure to
connect the input and output tubing correctly will result in poor pressure
regulation.
5.3.2 FUEL AERATION SYSTEM COMPONENTS

The JFTOT III Fuel Aeration System includes the following components:
• Air Pump
• Dryer Assembly
• Relative Humidity Sensor
• Flow Meter
• Tubing and Fittings
5.3.2.1 Air Pump

The aeration pump operates on 24VDC and provides a flow rate in
excess of 1.5 L/min.
To replace the aeration pump (Figure 5-36), simply remove the
tubing, unplug the power connection from the wire harness and
slide the pump up and out of the clamp mount.
Use the steps in reverse order for replacing the air pump.

FIGURE 5-36
AERATION AIR PUMP
Aeration
Supply Pump
Power Cable
Aeration Supply Connector
Pump (AL-60113)
5.3.2.2 Dryer Replacement

See Subsection 5.2.2 “Aeration Dryer Replacement”.
5.3.2.3 Relative Humidity (RH) Sensor Replacement

The relative humidity sensor (Figure 5-47) detects the amount of
moisture in the air being supplied to the fuel aeration system. The
computer reads this value and determines if the humidity level is
over the maximum amount allowed (typically 20% RH). The 5-
VDC reference voltage on the PC Interface PCB must be adjusted to
5.00 VDC in order to ensure the correct computer response (e.g.,
5.00VDC=100% RH).
Perform the following steps to replace the RH sensor.
FIGURE 5-37
RELATIVE HUMIDITY (RH) SENSOR
RH Sensor Cable
Connector Air Output
Tube Fitting
RH Sensor
(AL-92243)
Air Input
Tube Fitting Mounting
Screws (x2)
1. Switch off the power at the back panel power switch.

2. Remove the cable connector from the top of the sensor.
3. Remove the input and output lines from the sensor.
4. Remove the two mounting screws under the mount.
5. Use the steps in reverse order (4-1) as a guide for replacing the
sensor. Do NOT over tighten fittings. For procedures on
installing new tubing, refer to Section 5.3.4.

5.3.2.4 Aeration Flow Meter Replacement

The aeration flowmeter (AL-58037) can be replaced by performing
the following steps.
Aeration tubing consists of 5/16” flexible Tygon tubing (AL-49292)
used to connect the pump and 1/8” nylon tubing for all other
aeration connections.
1. Remove the power to the JFTOT III.
2. Remove the right side panel and locate the aeration flowmeter
(see Figure 5-38).
3. Remove the air-input and air-output lines.
FIGURE 5-38
AERATION FLOWMETER
Aeration
Flowmeter
Elbow Fitting Output Line
Flowmeter Fitting
Housing Nut
Mount Bracket
Mounting Nuts
Aeration
Flowmeter
Elbow Fitting Input Line
Fitting
CAUTION: Use a backup wrench to hold the housing nuts for the elbow fitting when
loosening or tightening the flowmeter fittings. Failure to do so may result in
the threads of the flowmeter plastic housing being stripped.
4. Remove the elbow fittings from the flowmeter housing nuts.

5. Remove the two mounting nuts and then remove the
flowmeter mounting bracket and the flowmeter.
6. Use the removal steps in reverse order as a guide to replace the
flowmeter. Install Teflon tape over pipe fitting threads only.
Do NOT over tighten fittings. For procedures on installing
new tubing, refer to Section 5.3.4. “Tubing and Fittings”.
5.3.3 COOLING SYSTEM COMPONENTS

The coolant system (Figure 5-39) pumps a 50/50 mixture of water and ethylene
glycol (anti-freeze) through the bus bars to keep them cool (approximately 40°C)
during operation. This establishes a specific hot spot inside the tube at the tip of the
thermocouple inside the heater tube. The coolant reservoir should be about half full
while the coolant pump is in operation.

The coolant system uses two types of tubing for lines. The pump lines are 5/16" dia
flexible Tygon® tubing (AL-49292) and the remaining tubes are 1/4" dia. Teflon
tubing (AL-49291). See Section 5.3.4. “Tubing and Fittings”.
The JFTOT III Cooling System includes the following major components:
• Coolant Pump and Bypass Valve
• Flow Meter
• Radiator and Fan Assemblies
• Coolant Container
• Coolant Jets and Bus Bars
• Tubing and fittings
CAUTION: Use only distilled or deionized water in the cooling water container. Failure
to do so may cause deposits to build up in the coolant system.
FIGURE 5-39
COOLANT SYSTEM
Coolant Fluid
Container
(AL-17683)
Coolant Fluid Pump
(AL-60119)
Coolant Fluid
Pump Check Valve
(AL-93109)
Coolant Fluid Fan

(AL-61009-115)
Coolant Fluid Radiator

(AL 60684)
5.3.3.1 Coolant Pump Assembly and Check Valve Replacement

The coolant fluid pump is powered by a directly-coupled 24VDC
motor. The pump moves the liquid through the coolant system at a
flow rate in excess of 40 L/hr (10 gal/hr). A check valve is installed
between the input and output lines of the pump to act as a pressure
regulator. If the coolant system pressure increases or becomes
clogged, the check valve opens to reduce the pressure felt by the
pump.
The pump motor can be replaced by performing the following steps.
power connector.

2. Remove the right side panel and locate the coolant fluid pump
as shown in Figure 5-40. Normal flow is indicated by solid
arrows. A dashed arrow indicates the flow through the check
valve when the line is clogged.
FIGURE 5-40
COOLANT FLUID PUMP ASSEMBLY
Coolant Fluid
Container Coolant Fluid
Pump
Snap-Lock
Mounting
Clamp
Check Valve
Power Cable
Connector
3. Disconnect the pump power cable connector.

4. Drain the coolant fluid from all lines and then flush the system
with clean water.
5. Cut the tie wraps holding the input and output lines to the
pump and then pull the input and output lines off of the pump.
6. Use a flat-blade screwdriver as a wedge to open the snap-lock
(Figure 5-40) on the pump motor mounting clamp and remove
the pump.
7. The check valve can be removed by simply removing the input
and output lines and then removing the valve.
CAUTION: When a replacement check valve is installed, ensure the check valve is
installed with the arrow on the side of the valve pointing toward the coolant
delivery line to the pump.
CAUTION: When a replacement coolant pump is installed, ensure the direction of flow
is down as indicated by the label on the pump.
8. Use the steps in reverse order (7-1) as a guide for replacing

the pump and check valve. Install Teflon tape over non-
swaged fitting threads only. Do NOT over tighten fittings
during replacement. For procedures on installing new tubing,
refer to Section 5.3.4. “Tubing and Fittings”.

9. Refill the system with coolant (50/50 distilled water and

antifreeze) and then circulate coolant through the system to
ensure proper leak-free operation.
10. Observe the coolant flow meter ball position is in the
green range.
11. After the correct coolant flow is obtained, test the check valve
by opening the flow control valve all the way (max flow and
min pressure). The ball should float up to about 75% of the
top. If the ball goes to the top of the flow meter, the check valve
is possibly installed upside down or the ball valve is stuck
inside the check valve.
NOTE: To dislodge the ball inside the valve, clamp off the input lines, remove the
lines, remove the inlet “T” fitting and use a pencil eraser to dislodge the ball
valve. Reassemble the valve, remove the clamps and retest.
5.3.3.2 Flow Meter Replacement

The coolant flow meter is located above the heater-tube test area on
the right-hand side.
The Coolant Fluid Flow Meter can be replaced by performing the
following steps.
power connector.
2. Remove the right side panel and locate the coolant fluid flow
meter as shown in Figure 5-41.
FIGURE 5-41
COOLANT FLOW METER
Coolant Flowmeter
(AL-58036)
Plastic Shield Coolant Fluid Flowmeter
Output Line Fitting
Mount Bracket
Mounting Nuts
Coolant Fluid
Flowmeter Input Line
Fitting
3. Drain the coolant fluid from all lines.

4. Remove the coolant fluid input and output lines.
See Figure 5-41.

CAUTION: Use a backup wrench to hold the housing nuts for the elbow fitting when
loosening or tightening the flowmeter fittings. Failure to do so may result in
the threads of the flowmeter plastic housing being stripped.
5. Remove the two mounting nuts and then remove the

flowmeter mounting bracket and the flowmeter.
6. Use the removal steps in reverse order (Steps 6-1) as a guide to
replace the flowmeter. Install Teflon tape over the pipe threads
on the flowmeter IN and Out fittings. Do NOT over tighten
fittings. For procedures on installing new tubing, refer to
Section 5.3.4. “Tubing and Fittings”.
7. Refill the system with coolant (50/50 water and antifreeze)
and then circulate coolant through the system to ensure proper
leak-free operation.
8. Observe the coolant flowmeter ball can be adjusted in the
green range.
5.3.3.3 Radiator and Fan Replacement

Heated coolant from the bus bars is carried through the radiator and
removed by the air being blown across the radiator coils by the fan.
The radiator and/or fan can be replaced by performing the following
steps.
power connector.
2. Remove the right side panel and locate the radiator and fan
assembly (see Figure 5-42).
FIGURE 5-42
RADIATOR AND FAN ASSEMBLY
Coolant Fluid Container
Input Line Fitting
(Output Line Fitting on
bottom of Container)
Bracket Mount Nut
Radiator Coolant
Output Line Fitting
Radiator Coolant Input

Radiator Mount Line Fitting
Screws
Fan Power Cable Connection
Fan (61009-115V)
Radiator (AL-60684)

3. Disconnect the power cable to the fan.

4. Drain the coolant fluid from all lines.
5. Remove the input and output coolant fluid lines at the radiator
and at the coolant fluid container (see Figure 5-42).
6. At the back of the JFTOT, remove the four grill mounting
screws (Figure 5-43) from the radiator only. These screws hold
the fan, the radiator and the grill to the back panel.
FIGURE 5-43
COOLANT JETS AND BUS BAR ASSEMBLY
Fan Grill Mounting

Screws (x4)
7. To remove the radiator and coolant assembly, remove the

bracket mounting nut (Figure 5-42) and carefully lift out the
assembly. The fan should remain in place after the radiator is
removed.
8. The fan can now be removed with or without the grill.
9. To remove the radiator from the bracket, remove the two
radiator mounting screws (Figure 5-42) at the top of the
radiator.
replace the radiator or fan. Do NOT over tighten fittings. For
5.3.3.4 Coolant Container Replacement

The coolant container (Figure 5-44) can be replaced by performing
the following steps.
power connector.
2. Remove the right side panel and locate the radiator and fan

FIGURE 5-44
COOLANT CONTAINER
Coolant Container
(AL-17683) Coolant Container
IN Fitting
Mounting
Nuts (x2)
Coolant Container
OUT Fitting
3. Drain the coolant system.

4. Remove the input and output coolant fluid lines (Figure 5-44).
5. Remove the two coolant container mounting nuts and remove
the coolant container.
replace the coolant container. Install Teflon tape over pipe
fitting threads only. Do NOT over tighten fittings. For
5.3.3.5 Coolant Jets and Bus Bars Replacement

The bus bars are hollow to allow water cooling to be injected from
jet tubes and circulated back out over the jet tubes. The bus bar jets
deliver coolant to the end of the bus bars and allow the coolant to
return along the inside surface of the bus bar and to the radiator.
The following cutaway drawing in Figure 5-45 shows the properly
installed bus coolant jets and lines.
FIGURE 5-45
COOLANT JETS AND BUS BAR ASSEMBLY
(AL-97139)
(AL-10774)

5.3.3.6 Coolant System Jet Tube Replacement
NOTE: Refer to “Drawings” in Section 5.9 for the flow diagram and tube routing
diagrams.
When replacing the coolant jet tube, perform the following steps.
1. Insert the tube into the bus bar and slide the ferrule and nut in
place as shown in Figure5-46 A.
2. Insert the tube into the bus bar until it bottoms out.
3. Finger tighten the nut and then scribe the tube at the back of
the fitting as shown in Figure 5-46B.
FIGURE 5-46
COOLANT JET TUBES INSTALLATION
A B
Ferrule
Nut
.
4. Retract the tube ¼” as shown in Figure 5-47 and then use an
open-end wrench for the nut and a backup wrench for the
T-fitting to swage the nut and ferrules onto the tube. Install
Teflon tape over pipe fitting threads only. Do NOT over
tighten fittings. For procedures on installing new tubing, refer
to Section 5.3.4. “Tubing and Fittings”.
FIGURE 5-47
JET TUBE RETRACTION
¼” Scribe Mark
Output Fitting
5. Test the connection for flow by blowing into the tube and
checking for air flowing out the output fitting

5.3.4 TUBING AND FITTINGS
5.3.4.1 Metal, Nylon or Teflon Tubing and Swagelok Fittings
NOTE: Refer to the “Drawings” in Section 5.9 for the flow diagram and tube
routing diagrams.
When installing new lines or tubing, make sure you use new
Swagelok ferrules and swage them properly. Swagelok fittings are
installed as follows:
1. Install the two-part ferrule and nut onto the tube as shown in
Figure 5-48.
FIGURE 5-48
SWAGED FITTINGS ASSEMBLY (TYPICAL)
Nut
Fitting
Tubing
Ferrules
2. Insert tubing into the Swagelok fitting. Make sure that the
tubing rests firmly in the shoulder of the fitting and the nut is
finger-tight.
3. Before tightening the Swagelok nut, use a scribe (or pencil) to
mark the nut at the 12-o’clock position as a reference.
4. Hold the fitting body steady with a backup wrench and tighten
the nut as follows:
• For 1/8" tubing: 3/4 turns to the 9-o’clock position
• For 1/4" and larger tubing: 1-1/4 turns
(past 12-o’clock to the 3-o’clock position)
CAUTION: Install Teflon tape over non-swaged fitting threads only. Do NOT over
tighten fittings. For 3/16" diameter and smaller tubing, tighten the nut an
extra 3/4 turns. Tubing 1/4"and larger requires tightening the nut an extra
1-1/4 turns. When retightening already swaged fittings tighten to snug, DO
NOT turn the nut an extra 3/4 turn.
5.3.4.2 Flexible Tygon Tubing and Swagelok or Barbed Fittings
NOTE: Refer to the “Drawings” in Section 5.9 for the flow diagram and tube
routing diagrams.

When installing new lines or tubing, make sure you use new
Swagelok ferrules and swage them properly. The brass insert may
be reused. New Tygon tubing is installed onto Swagelok fittings as
follows:
1. Cut the tubing to length.
2. Install the two-part ferrule and nut onto the tube as shown in
Figure 5-48
3. Install brass insert into the end of tubing to be swaged.
4. Insert tubing into the Swagelok fitting. Make sure that the
tubing rests firmly in the shoulder of the fitting and the nut is
finger-tight.
5. Before tightening the Swagelok nut, use a scribe (or pencil) to
mark the nut at the 12-o’clock position as a reference.
6. Hold the fitting body steady with a backup wrench and tighten
the nut as follows:
• For 3/16 and 1/8" tubing: 3/4 turns to the 9-o’clock position
• For 1/4" and larger tubing: 1-1/4 turns
(past 12-o’clock to the 3-o’clock position)
New Tygon tubing is installed onto barbed fittings as follows:

1. Cut the tubing to length.
2. Push the tubing over the barbed fitting as far as it will go.
3. Install a tie wrap or clamp around the tubing and tighten the
tie wrap or clamp over tubing and barbed fitting.
5.3.5 POWER SUPPLY AND HEATER SUPPLY SYSTEM

The JFTOT III Power Supply and Heater Supply System includes the following
major components:
• Power Entry Module
• Step Down Transformer
• Power Distribution PCB
• 24-VDC Power Supply
• SCR Heater Control Module
• Low-Voltage Transformer
5.3.5.1 Power Entry Module Replacement

The power entry module can be mechanically configured for
115VAC or 230VAC by performing the steps in Section 5.4.5.
servicing internal components.

Perform the following steps to replace the power entry module

(80085).
power connector.
2. Remove the right side panel and locate the power entry module
FIGURE 5-49
POWER ENTRY MODULE CONNECTIONS
Spring
Clips
Blue (D)
Brown (A)
Violet (C)
Orange (B)
Green (Gnd)
3. Note the positions of each wire and then carefully, pull each of
the spade connectors (Figure 5-49) from spade terminals on
the module. Care must be taken not to break the wires.
4. Use a flat-blade screwdriver to press down the plastic spring-
clips (Figure 5-49) at the top and bottom corners of the
connector while lifting the back of the connector to push the
module out of the opening.
replace the module.
5.3.5.2 Step-Down Transformer Replacement

The step-down transformer delivers 115VAC to the JFTOT III
regardless of whether the input voltage from the power entry
module is 230 VAC or 115 VAC.
Perform the following steps to replace the step-down transformer.

power connector.
2. Remove the right side panel and locate the step-down
transformer as shown in Figure 5-50.

FIGURE 5-50
STEP-DOWN TRANSFORMER
Primary 1 (115VAC ) (Brown)

Primary 2 (115 VAC ) (Orange)
Primary 1 (0 VAC) (Violet)
Primary 2 (0 VAC) (Blue)
Step-Down Transformer
(AL-90698)
Secondary (0 VAC) (White)
Secondary (115 VAC ) (Black)
3. Note the positions of each wire and then remove the six wires
connected (Figure5-50) to the transformer terminals.
4. While holding the transformer, remove the mounting nuts (4)
in the corners that hold the transformer to the enclosure wall
and remove the transformer.
replace the transformer.
5.3.5.3 Power Distribution PCB and SSR Module Replacement

Perform the following steps to replace the Power Distribution PCB
and solid-state relay (SSR) modules.
power connector.
2. Remove the left side panel and locate the power distribution
PCB as shown in Figure 5-51.

FIGURE 5-51
POWER DISTRIBUTION PCB
P1 – Relay Control
K1 Mounting Screws
(x4)
Connector Locks
P5 – 115 VAC Out
K2 Mounting Screws
P4 – To PC Power (x4)
(115 VAC)
P3 – To Step-Down
Transformer P2 – 115/230 VAC from
Power Entry Module
3. Remove all five connectors (Figure 5-51) by pressing down on

the ends of both connector locks and pulling out on the
connector.
4. Remove the eight screws (Figure 5-52A) holding the PCB to
the K1 and K2 solid-state relay modules and then remove the
PCB away from the relay modules.
5. To remove the SSR Modules simply remove the two mounting
screws from each SSR module (Figure 5-52B) and then remove
the modules from the enclosure wall.
FIGURE 5-52
POWER DISTRIBUTION PCB MOUNTING SCREWS
A B
D5 LED P1 1
F5 – Fan Fuse K1 – Base Power SS Relay
(50003)
D4 LED
D11 LED
F5 – Drive Pump Fuse
P5
D3 LED 3 1
F3 – 24 VDC Supply Fuse
D2 LED
SS Relay Mounting Screws
F2 – Heater & Fan 2 Fuse 15 13
D1 LED
F1 – PC Fuse
D12 LED
P3 P2
P4 K2– Heater SS Relay
Power Distribution 1 (50003)
PCB (AL-54743) 1 4
1

replace the Power Distribution PCB.

5.3.5.4 Power Distribution PCB (AL-54743) LED Description

The following table provides locations and description for LED
status indicators used in the Power Distribution PCB. See Figure
5-52A for locations
TABLE 5-2
STATUS LEDS ON POWER DISTRIBUTION PCB
LED Reference. Color* Description

D1 F1 Red Indicates status of 4A fuse F1
D2 F2 Red Indicates status of 4A fuse F2
D3 F3 Red Indicates status of 1.5A fuse F3
D11 K1 BASE Green Digital control signal from watchdog timer on Interface PCB.
POWER This turns on relay K1 to power the HPLS pump and the 24VDC
RELAY power supply.
D12 K2 Green Digital control signal from SSR2 on Interface PCB. This turns
HEATER on relay K2 to power the heater SCR.
RELAY
* NOTES: Red LED On (D1-D5)= Fuse Blown;
Green LED On (D11 & D12)= Power On
NOTE: Status LEDs D1-D5 are located next to their respective fuses, and are visible
externally from the back of the JFTOT. The Green D11 and D12 LEDs are
visible internally to indicate K1 and K2 power status.
5.3.5.5 Power Distribution PCB Cable Connections

Mating connectors required to plug into the Power Distribution
PCB are listed in the tables below.
NOTE: Refer to the Cable Pin-Out tables below and the JFTOT III Electrical
Schematic in “Drawings” Section 5.9.
TABLE 5-3
P-1CONNECTOR: RELAY CONTROL INPUT (4-CIRCUIT AMP MTA-156 20AWG)
Pin # Function
1 + Base power relay
2 - Base power relay
3 + Bus heater relay
4 - Bus heater relay

TABLE 5-4
P-2 CONNECTOR: 115/230V POWER INPUT (6-PIN AMP MATE-N-LOK)
Pin # Function
1 Safety ground
2 Ground
3 Line-A
4 Line-B
5 Line-C
6 Line-D
TABLE 5-5
P-3 CONNECTOR: STEP-DOWN TRANSFORMER (6-PIN AMP IN-LINE MATE-N-LOK)
Pin # Function
1 Primary-2 115V
2 Primary-1 0V
3 Primary-2 0V
4 Primary-1 115V
5 Secondary 0V
6 Secondary 115V
TABLE 5-6
P-4 CONNECTOR: PC POWER OUTPUT (3-PIN AMP MATE-N-LOK)
Pin # Function
1 Ground
2 Neutral
3 115/230VAC
TABLE 5-7
P-5 CONNECTOR: 115V OUT (15-PIN AMP MATE-N-LOK)
Pin # Function
1 Ground, Fan-1
2 Neutral, Fan-1
3 115VAC, Fan-1
4 Ground, Drive pump
5 Neutral, Drive pump
6 115VAC, Drive pump
7 Ground, 24VDC power supply
8 Neutral, 24VDC power supply
9 115VAC, 24VDC power supply
10 Ground, Fan-2 (on radiator)
11 Neutral, Fan-2
12 115VAC, Fan-2
13 Ground, Heater SCR
14 Neutral, Heater SCR
15 115VAC, Heater SCR

5.3.5.6 24-VDC Power Supply Replacement

Perform the following steps to replace the 24-VDC Power Supply.
power connector.
2. Remove the right side panel and locate the 24-VDC Supply as
FIGURE 5-53
24-VDC SUPPLY
Cover Screws
(x4)
24-VDC Power
Supply
(AL-90697)
3. Remove the four thumbscrews from the protective cover and

remove the cover from the power supply.
4. Remove the 24-VDC input connector (Figure 5-54), the
ground wire spade connector and the 115-VAC connector from
the supply.
FIGURE 5-54
24-VDC SUPPLY REMOVAL
Standoffs (x4)
115-VAC Input
24-VDC Output
Connector
Connector
Ground Wire
5. Remove the four standoffs and then remove the power supply.


replace the 24-VDC PCB.
5.3.5.7 Heat Control Assembly Replacement

Perform the following steps to replace the Heat Control Assembly.
power connector.
2. Remove the right side panel and locate the heater control
3. Remove the wires (Figure 5-55) going to the SCR heater
control at screw-terminals 2, 3, Gnd, 7 and 8.
4. Disconnect the RMS current transformer lead connector.
5. Remove the heater power cables at the upper and lower bus
bar assemblies.
6. Remove the four mounting nuts (Figure5-55) on the left and
right sides at the bottom of the mounting bracket.
FIGURE 5-55
SCR HEATER CONTROL
Low-Voltage Transformer
(AL-90719)
Upper Bus Bar Heater Power

Supply Cable (AL-97139) Heat Control Assembly
Mounting Screws (x 4)
RMS Current Sensor
(AL-90718) RMS Current Transformer
Connector
Lower Bus Bar Heater Power High (Red) (8)
Supply Cable Low (Green) (7)
4-20 ma Signal In
SCR Heater Control 115-VAC Input

(AL-83193) Connectors
(2, 3 & Gnd)
7. Remove the heat control assembly from the enclosure.

replace the Heat Control Assembly.

5.3.5.8 SCR Heater Control Module Replacement
NOTE: Refer to “Adjusting the SCR” in Section 5.4.3.
Perform the following steps to replace the SCR heater control.
power connector.
2. Remove the right side panel and locate the SCR heater control
(Figure 5-56).
3. Use a screwdriver to remove the two wires (5 & 6) on the left
and the three wires (2,3 & Gnd) on the right. Use a small flat-
blade screwdriver to remove the two wires (7 & 8) on the back
of the SCR heater control. See Figure 5-56.
FIGURE 5-56
SCR HEATER CONTROL
High (Red) (7)

4-20 ma Signal In
Low (Green) (8)
8 7
SCR Heater Control
Module (AL-83193)
Low-Voltage Hot 5 2 Line
Transformer (Violet) (Brown) 115-VAC In from
Primary Leads Neutral 6 3 Neutral Power Distribution
(Blue) (Blue) PCB Connector (P5)
Gnd
Ground
Mounting Nuts
(x4)
4. Remove the four mounting nuts at the base of the SCR heater
control and then remove it from the enclosure.
replace the SCR heater control.
5.3.5.9 Low-Voltage Transformer Replacement

Perform the following steps to replace the low-voltage transformer.

power connector.
2. Remove the right side panel and locate the low-voltage
3. Remove the entire heat control assembly as described in
Section 5.3.5.7.
4. Unwind and remove the bus-bar heater cable from the
transformer.
5. Remove the two primary input leads (Figure 5-57) on the right
side of the transformer.
FIGURE 5-57
LOW-VOLTAGE TRANSFORMER
Mounting Screws
(x2)
Low Voltage
Transformer Primary input
(AL-90719) Voltage from SCR
Bus-Bar Heater Power

Cable (AL-97139)
To Upper and Lower Bus
Bar Assemblies
Three Wraps
6. Remove the transformer from the enclosure.

replace the low-voltage transformer.
5.3.5.10 RMS Current Transformer Replacement

Perform the following steps to replace the low-voltage transformer.
power connector.
2. Remove the right side panel and locate the RMS current

3. Disconnect the heater power cable at the upper or lower bus-

bar assembly.
4. Remove the two mounting screws (Figure 5-58) at the base of
the RMS current transformer.
5. Slide the RMS current transformer off the end of the power
cable.
FIGURE 5-58
RMS CURRENT TRANSFORMER
Current Transformer
(AL-90720)
Bus-Bar Power
Cable
Mounting Nuts
(x2)

replace the RMS current transformer.
5.3.6 CONTROL SYSTEM COMPONENTS

The JFTOT III Control System includes the following components:
• Touchscreen and Computer Subsystem
• DAQ PCB
• Computer Interface PCB
5.3.6.1 JFTOT III Embedded Computer Replacement

The JFTOT III embedded computer subsystem provides user
interface touch screen, Windows-based PC Pentium III processor
control and a DAQ interface to the JFTOT III hardware in a single
package. The computer assembly is shown in Figure 5-59.

FIGURE 5-59
JFTOT III EMBEDDED COMPUTER
JFTOT III Embedded

Computer and Touch
Screen (32202)
Computer and
Touch Screen DAQ PCBs
Display
CD ROM Drive
Perform the following steps to remove and replace the JFTOT III
embedded computer and touchscreen subsystem.
power connector.
2. Remove both side panels and locate the Computer subsystem
and connectors as shown in Figure 60.
3. Disconnect the power cord, keyboard, mouse, USB (x2), serial
I/O, DAQ and PC power switch cable connectors. See Figure 5-
60.
FIGURE 5-60
COMPUTER CABLES
DAQ Cable
Connector
115VAC Power
Keyboard and Mouse

USB (x2)
Serial I/O
PC Power Switch
Connector
4. Disconnect the safe power-on switch cable connector going to

the computer power switch on the JFTOT III front panel.

5. Remove the eight screws around the perimeter of the PC

holding the computer to the front panel as shown
Figure 5-61A. Ensure the PC subassembly does not fall
forward out of the enclosure after the screws have been
removed.
6. From the front of the JFTOT, carefully remove the PC
subassembly from the enclosure as shown in Figure 5-61B.
FIGURE 5-61
COMPUTER REMOVAL
A B
PC Mounting
Screws (x8)

replace the embedded PC Subsystem.
NOTE: Ensure the computer power switch located on the back of the PC near the
power cord is always switched to the ON position.
5.3.6.2 Touchscreen Alignment

The touchscreen alignment procedure defines the active area of the
touchscreen and aligns the active area with the underlying video.
After new TouchWare driver software has been installed, video
resolution has been changed, or adjustments are made to the vertical
or horizontal, the following alignment procedure must be
performed.
CAUTION: Never use a sharp tool such as a pen or pencil to point to items on the
touchscreen. Doing so will permanently damage the screen. Use a stylus,
fingertip or a soft plastic tool to physically select items on the screen.
1. Switch on the power to the PC

2. At the MS Windows screen, locate the “e-Turbo” icon and

double-click the icon to display the Diagnostics Utility panel as
FIGURE 5-62
DIAGNOSTIC UTILITY SCREEN
3. Select the Calibration tab on the utility panel to display the

Calibration options as shown in Figure 5-63.
FIGURE 5-63
CALIBRATION SCREEN
4. Select the “Calibrate 25 pt” option box to display the Calibrate

25-Points screen in Figure 5-64.

FIGURE 5-64
CALIBRATE 25 POINTS SCREEN
Timer Status Bar
NOTE: The time for selecting each point on the screen is limited as indicated by the
movement of the status bar at the bottom of the screen. If the diamond has
not been pressed before the bar is completely yellow, the option box appears
and the process must be started over by selecting YES.
5. Position a stylus at the exact center of the blinking green

diamond (Figure 5-65) and press until the blinking stops and
the next “X” becomes a blinking diamond.
FIGURE 5-65
CAL POINT SELECTION
6. Continue this procedure until all 25 positions have been

pressed.
7. After the last position has been pressed, the calibration screen
appears with the option box stating the calibration has finished
with the option of calibrating again as shown in Figure 5-66.
Select NO to continue or YES to begin the calibration again.

FIGURE 5-66
CALIBRATION-REPEAT SELECTION BOX
8. After selecting NO another option box appears (Figure 5-67)

for saving the calibration as a file. Press YES to save the file or
No to discard the calibration data.
FIGURE 5-67
SAVE-CALIBRATION SELECTION BOX
9. After selecting YES, the standard MS Windows “Save AS”

window appears to allow the file to be saved in the MY
Documents folder. The file can be saved in another folder by
clicking the down arrow and selecting the folder.
10. Type a name for the file (e.g., TS Cal and today’s date) in the
File Name box as shown in Figure 5-68. If not selected, press
the down arrow and select Parameters as the “Save as type”.
11. Press the SAVE button to save the file in the selected folder.
FIGURE 5-68
WINDOWS SAVE-AS SCREEN
Enter File Name
12. After the calibrate screen appears, press the OK button to

return to the MS Windows desktop.
13. Find the cursor on the desk top and then press the stylus at the
point of the arrow as shown in Figure 5-69.

FIGURE 5- 69
CURSOR ALIGNMENT
This concludes the LCD alignment procedures..
5.3.6.3 Data Acquisition (DAQ) PCB Installation

The DAQ PCB is installed in the JFTOT III computer enclosure as a
hardware interface between the user commands and the JFTOT III
functional elements. See Section 5.5.2 for software installation
procedures.
The PCI-6023E Multifunction DAQ PCB was installed and
configured in the JFTOT III at the factory before shipment and
should not need to be reinstalled and configured unless the
computer or DAQ board has been replaced. Before the computer is
installed into the JFTOT III, the required software and hardware
need to be installed onto the computer.
The DAQ board (6024E) will require NI-DAQ 7.2 (Traditional NI-
DAQ) or later software to be installed unless the correct version is
already installed in the PC. NI-DAQ-7 is a two-CD set labeled Disk
1 of 2 and Disk 2 of two. Later versions of NI-DAQ software is
contained in a single disk. The NIDAQ Software should be installed
prior to installing the DAQ PCB if a working version is not
installed.
If it becomes necessary to reinstall the DAQ PCB, perform the
following steps.
CAUTION: The DAQ PCB contains static-sensitive parts that can be damaged when
touched. The installation of the Multifunction DAQ board should be done at
a static-free workstation.
1. Remove the PC from the JFTOT front panel as described n

Section 5.3.6.1.
2. Attach an antistatic wrist band connected to a good earth
ground and place the computer face down at a static-free
workstation. Make sure it is not placed on any surface that will
scratch or damage the front or the LCD screen of the computer.

3. Remove the plastic computer back cover as listed below and as

3.1 Remove the tie wrap that holds the switch cable to the
computer chassis.
3.2 Remove the seven screws that hold the back cover onto
the computer (see Figure 5-70).
3.3 Carefully remove the back cover. You may have to hold in
the CD panel to get it to clear the cover.
FIGURE 5-70
JFTOT III PC BACK COVER REMOVAL
PC Mounting
Screws (x3)
PC Mounting
Screws (x2)
Cut Tie-Wrap
PC Mounting
Screws (x2)
3.4 Remove the back cover being careful not to pull the
switch wire loose from the inside of the computer.
4. After the back cover has been removed, remove the metal
cover as listed below and as shown in Figures 5-71 and 5-72.
4.1 Remove the 6 screws (Figure 5-72 that hold the
metal cover.

FIGURE 5-71
JFTOT III PC METAL-COVER SCREW REMOVAL
4.2 Remove a seventh screw (Figure 5-72) on the other side

of the computer.
FIGURE 5-72
JFTOT III PC METAL COVER FINAL SCREW REMOVAL
CAUTION: Do not force the cover during removal. The metal cover has
interconnection circuitry attached that will be damaged unless the PC-board
edge plug is removed from the mating connector by alternately pulling up on
the cover one side at a time.
4.3 Carefully remove the metal cover as shown in Figure 5-73

by alternately pulling the cover one side at a time.

FIGURE 5-73
JFTOT III METAL COVER REMOVAL
5. Locate the two PCI expansion connectors in the top half of the
compartment as shown in Figure 5-74.
6. Loosen the screw that holds the protective cover (Figure 5-74)
to the inside expansion slot and remove the protective cover.
FIGURE 5-74
JFTOT III SLOT ACCESS COVER REMOVAL
7. Install the DAQ PCI card into the inside PCI expansion slot
and retighten the screw to hold the DAQ card securely in place

FIGURE 5-75
DAQ PCB INSTALLED
8. Carefully align the PCB connector with the mating connector

and replace the metal compartment cover. Ensure the
connector on the cover mates with the connector in the
computer.
9. Replace the 7 screws that hold the metal cover in place.
10. Insert the switch wire through the hole in the plastic computer
back and reinstall the back onto the computer.
11. Reinstall the 7 screws that hold the plastic cover in place as
shown in Figure 5-76. Refer to Figures 5-71 and 5-72 for screw
locations.
12. Tie-Wrap the ON/OFF switch cable back in place. prosperous
FIGURE 5-76
COMPUTER BACK COVER INSTALLED
13. The DAQ board must be configured as described in Section
5.3.6.4 “6024E DAQ PCI BOARD CONFIGURATION”.

5.3.6.4 6024E DAQ PCI Board Configuration

The PCI – 6024E DAQ PCI data acquisition board was installed and
configured in the JFTOT III at the factory before shipment and
should not need to be reconfigured. If it becomes necessary to
configure the DAQ board, perform the following steps.
1. Ensure the DAQ PCB has been properly installed as described
in subsection 5.3.6.3 and the driver software has been in
stalled as described in subsection 5.5.2.
2. Attach the keyboard, mouse and power cable to the computer.
3. Switch the computer on and press the momentary switch. The
computer should power up and load Windows XP.
4. The computer should inform you that it has found new
hardware. Wait until the computer identifies the 6024E DAQ
board and installs the drivers. The computer will inform you
that the drivers were installed and that the DAQ board is ready
for operation.
5. Double click the Measurement & Automation icon
(Figure 5-77) on the computer desktop.
FIGURE 5-77
JFTOT III MEASUREMENT AND AUTOMATION ICON
6. Double click on “Devices and Interfaces” file folder

(Figure 5-78) in the Configuration panel at the upper left
of the screen.
FIGURE 5-78
JFTOT III DEVICES AND INTERFACES FOLDER

7. Double click on “Traditional NI-DAQ Devices” File Folder as

shown in Figure 5-79
FIGURE 5-79
CONFIGURATION SCREEN
8. Right click on the PCI-6024E (Device 1) and click on

Properties as shown in Figure 5-80.
FIGURE 5-80
PCI-6024E – PROPERTIES
9. The following screen (Figure 5-81) will appear. Make sure that
the Device Number is 1.
FIGURE 5-81
CONFIGURING DEVICE NUMBER

10. Click the “AI” tab and In the MODE select control
(Figure 5-82), select “Referenced Single Ended” then click
“Apply”..
FIGURE 5-82
AI MODE SELECT
11. Click on the “System” tab (Figure 5-83) and then click “Test
Resources”.
FIGURE 5-83
SYSTEM – TEST RESOURCES SELECT
12. A message should appear that states that the device passed all
tests.
5.3.6.5 Computer (PC) Interface PCB (AL-54741)

The computer Interface PCB provides a platform for connectivity
between the DAQ PCB and the JFTOT III input/output devices.
Locations for the solid state relays and amplifiers described in the
tables are shown in Figure 5-84.
NOTE: The solid-state relays and amplifier modules used in the PC Interface PCB
are supplied as separate parts and are not included with the replacement PC
interface PCB. The SSR and amplifier modules should be removed from the
interface PCB being replaced and then, if not defective, reinstalled into the
replacement interface PCB.

FIGURE 5-84
JFTOT III COMPUTER INTERFACE PCB
4-20ma Heat Cont. Amp K1 - Watchdog Timer

Module (45279) Base Power (45280)
RMS Amps Amp SSR2 - Drive Pump Enable
Module (45278) (AL-62461)
SSR1 – Aeration (AL-62461)
RMS Volts Amp
SSR7 - Bus Heater Relay &
Module (45277)
Water Pump (AL-62461)
Bus-Bar Temp Amp SSR6 - DP Bypass Valve
Module (45276) (AL-62461)
Sample In Temp Amp SSR5 - DP– Vent Valve
(AL-62461)
Module (45276)
SSR4 - DP+ Vent Valve
Heater Tube Temp Amp (AL-62461)
Module (45276) SSR3 – System Vent Valve
(AL-62461)
System Pressure Amp
Module (AL-24638)
DP Amp Module
(AL-24638)
To remove the PC Interface PCB, proceed as follows:

power connector.
servicing internal components. Ensure that power lines are removed from
the power source before continuing.
2. Remove the left side panel and locate the PC Interface PCB as
shown previously in Figure 5-1A.
3. Remove each of the cables attached to the PC Interface PCB.
4. Remove the mounting screws from the PCB and remove the
PCB.
5. Remove the SSR and amplifier modules and retain for use in
the replacement PCB.
replace the PC Interface PCB.
The JFTOT III provides control through solid state relays modules
(SSRM) plugged into the computer interface PCB board which
provide electrically isolated switching functions. A status LED (light
emitting diode) is located next to each SSRM for visual indication of
the ON/OFF condition. The following list (Table 5-8) describes the
function of each SSRM and the state indicated by the lighted LED.

TABLE 5-8
SOLID-STATE RELAY MODULE (SSRM) FUNCTIONS
SSR# Function LED Lit

1 Aeration Pump (SSR1) ON
2 Fuel Drive Pump Enable (SSR2) ON
3 System Vent Solenoid Controlled Valve (SSR3) OPEN
4 DP + Vent Solenoid Controlled Valve (SSR4) OPEN
5 DP – Vent Solenoid Controlled Valve (SSR5) OPEN
6 DP Bypass Solenoid Controlled Valve (SSR6) OPEN
7 Bus Heater Relay and Coolant Pump (SSR7) ON
A Watch-Dog Timer Relay (K1) on the Computer Interface PCB
controls the Base Power Relay on the Power Distribution PCB,
which connects 115 VAC to the following components.
• Drive Pump
• 24 VDC Power Supply
The watch-dog timer relay will remove power to the components
after a set time if a computer problem exists.
Amplifier modules on the computer interface PCB provide signal
conditioning for the following inputs or outputs.
• Tube, Sample and Bus-Bar Temperatures
• DP Transducer
• System Pressure Transducer
• RMS Amps (through the heater tube)
• RMS Volts (Across the heater tube)
• Heater Control 4-20ma (DAQ0OUT)
Refer to the Cable Pin-Out tables below and the JFTOT III PC
Interface Drawing in Section 5.9.
TABLE 5-9
P2 CONNECTOR: VENT AND DP SOLENOIDS(10-PIN WAGO)
Pin # Function
1 + DP Bypass solenoid
2 - DP Bypass solenoid
3 + DP– Vent solenoid
4 - DP– Vent solenoid
5 + DP+ Vent solenoid
6 - DP+ Vent solenoid
Continued

TABLE 5-9 (CONTINUED)

P2 CONNECTOR: VENT AND DP SOLENOIDS(10-PIN WAGO)
Pin # Function
7 + System Vent solenoid
8 - System Vent solenoid
9 + Safety Vent solenoid
10 - Safety Vent solenoid
TABLE 5-10
P3 CONNECTOR: SYSTEM PRESSURE TRANSDUCER (4-PIN MOLEX MINI-FIT JR)
Pin # Function
1 - Excitation
2 + Excitation
3 - Signal
4 + Signal
TABLE 5-11
P-4 CONNECTOR: DP TRANSDUCER (6-PIN MOLEX MINI-FIT JR)
Pin # Function
1 - Excitation
2 - Excitation (-sense)
3 + Excitation
4 + Excitation (+sense)
5 - Signal
6 + Signal
TABLE 5-12
P5 CONNECTOR: 24VDC POWER SUPPLY INPUT (3-PIN AMP MTA-156 20AWG)
Pin # Function
1 +24VDC
2 No connection
3 Ground (24V return)
TABLE 5-13
P6 CONNECTOR: CONTROL RELAYS (10-PIN AMP MTA-156 20AWG)
Pin # Function
1 +Base Power Relay
2 - Base Power Relay (ground)
3 +Bus Heater Relay
4 - Bus Heater Relay (ground)
Continued


P6 CONNECTOR: CONTROL RELAYS (10-PIN AMP MTA-156 20AWG)
Pin # Function
5 - Drive Pump Enable (ground)
6 +Drive Pump Enable
7 +Aeration
8 - Aeration (ground)
9 +Water Pump
10 - Water Pump (ground)
TABLE 5-14
P7 CONNECTOR: ANALOG SIGNALS (12-CIRCUIT WAGO)
Pin # Function
1 + Tube temperature T/C (type K)
2 - Tube temperature T/C
3 + Sample temperature T/C (type K)
4 - Sample temperature T/C
5 + Bus Bar temperature T/C (type K)
6 - Bus Bar temperature T/C
7 Hi – RMS Volts input
8 Low – RMS Volts input
9 Hi – RMS Amps input
10 Low - RMS Amps input
11 Hi – 4-20mA Heater Control output
12 Low – 4-20mA Heater Control output
TABLE 5-15
P8 CONNECTOR: HUMIDITY SENSOR (3-PIN AMP MTA-100 24AWG)
Pin # Function
1 Analog ground
2 Signal
3 +5VDC Reference
TABLE 5-16
P9CONNECTOR: SPARE ANALOG SIGNALS (FUTURE) ( 8-PIN WAGO PN:232-308/026-000)
Pin # Function
1 + Input, Spare #1 (T/C or process)
2 - Input, Spare #1
3 + Excitation, Spare #2
4 + Input, Spare #2 (T/C, process or strain gage)
Continued


P9CONNECTOR: SPARE ANALOG SIGNALS (FUTURE) ( 8-PIN WAGO PN:232-308/026-000)
Pin # Function
5 - Input, Spare #2
6 - Excitation, Spare #2
7 Hi output, Spare #3 (volts or mA)
8 Low output, Spare #3
TABLE 5-17
P10 CONNECTOR: EXTRA DIGITAL CONTROL SIGNALS FROM DAQ CARD (FUTURE)
( 20-CIRCUIT RIBBON CABLE CONNECTOR)
Pin # Function
1 +5VDC
2 Digital ground
3 SCANCLK
4 EXTSTROBE
5 PFI0/TRIG1
6 PFI1/TRIG2
7 PFI2/CONVERT
8 Digital ground
9 PFI3/GPCTR1_SOURCE
10 PF14/GPCTR1_GATE
11 GPCTR1_OUT
12 PFI5/UPDATE
13 PFI6/WFTRIG
14 Digital ground
15 PFI7/STARTSCAN
16 PFI8/GPCTR0_SOURCE
17 PFI9/GPCTR0_GATE
18 GPCTR0_OUT
19 FREQ_OUT
20 Digital ground
TABLE 5-18
P11 CONNECTOR (14-CKT RIBBON): EXTRA ANALOG SIGNALS FOR DAQ CARD (FUTURE)
Pin # Function
1 ACH12
2 Analog ground
3 ACH13
4 Analog ground
5 ACH14
6 Analog ground
7 ACH15
8 Analog ground
9 +5VDC Reference (same as Humidity sensor)
10 Digital ground
Continued


P11 CONNECTOR (14-CKT RIBBON): EXTRA ANALOG SIGNALS FOR DAQ CARD (FUTURE)
Pin # Function
11 +5VDC
12 Digital ground
13 +24VDC
14 Digital ground
The names of the physical components (as labeled on the PCB) are
listed under the “Test Point” column. The “Reference” column lists
the function and the “Description” column describes the function.
The test point name and the reference name are located near the
component on the PCB.
NOTE: Test points TP7-TP27 are available on PCB revision A and later.
TABLE 5-19
TEST POINTS
Test point Reference. Description

TP1 DGND Digital ground, ground return path for digital circuits (relays SSR1-
SSR7 and K1).
TP2 +24V 24VDC from external power supply AL-90697, supplied to
connector P5 pin 1. This supplies power to the relays (SSR1-SSR7),
to the 5V reference (U13) and the 5V regulator (U12).
TP3 +5V 5V from internal voltage regulator (U12). This supplies power to
the amplifier modules (U1-U11).
TP4 PC+5V 5V from computer, supplied to connector P1 pins 34 & 35 through
50-conductor cable 16465. This supplies power to the watchdog
timer (K1).
TP5 +5VR 5V from internal voltage reference (U13). This supplies power to
the external humidity sensor 92243 through connector P8 pin 3.
TP6 AGND Analog ground, ground return path for analog circuits (amplifier
modules U1-U11 and U13). Analog and digital grounds tied
together only at connector P5 pin 3.
TP7 SIG Signal from external humidity sensor 92243, supplied through
connector P8 pin 2.
TP8 WATCHDOG Timing control signal from computer. The watchdog timer must
receive this digital timing control pulse from the computer at least
once every 2 seconds, otherwise the watchdog times out and turns
off, which then turns off the HPLC pump and the 24V power supply.
The status LED will stay on steady as long as the pulses have a
period less than 2 seconds.
TP9 TUBE TEMP. Amplified signal from Heater tube thermocouple AL-86303. The
amplifier module (U1) accepts a 0-500°C type K thermocouple input
and outputs a 0-5VDC signal. The amplified signal times 100
approximates the tube temp in °C (see note1).
Continued
1
Calibration of signals is performed in software by the JFTOT-III application program.


TEST POINTS

TP10 SAMPLE TEMP. Amplified signal from fuel sample thermocouple AL-86301. The
amplifier module (U2) accepts a 0-500°C type K thermocouple input
TP11 BUS BAR Amplified signal from bus bar thermocoupleAL-86302. The
TEMP. amplifier module (U3) accepts a 0-500°C type K thermocouple input
TP12 D.P. Amplified signal from differential pressure transducer AL-45042.
The amplifier module (U4) accepts a -30 to +30mV strain gage
input and outputs a –5 to +5VDC signal. The amplified signal
times 82.5 approximates the DP in mmHg (see note1). The amplifier
module outputs a 10VDC excitation voltage to power the transducer.
TP13 SYSTEM Amplified signal from system pressure transducer AL-45043. The
PRESS. amplifier module (U5) accepts a -30 to +30mV strain gage input
and outputs a –5 to +5VDC signal. The amplified signal times 150
approximates the system pressure in psig (see note1). The amplifier
module outputs a 10VDC excitation voltage to power the transducer.
TP14 RMS VOLTS Amplified signal of true RMS voltage measured across the heater
tube (between the bus bars). The amplifier module (U6) accepts a 0-
1VAC true RMS input and outputs a 0-5VDC signal. The amplified
signal times 0.2 approximates the voltage across the heater tube in
Volts.
TP15 RMS AMPS Amplified signal of true RMS current measured flowing through the
heater tube. The amplifier module (U7) accepts a 0-5AAC true RMS
input and outputs a 0-5VDC signal. The signal input into the
amplifier module is from a current transformer. The current
transformer is installed around the bus bar power cable and outputs
a 0-5 amp signal for a 0-400 amp current flowing through the power
cable, the same current flowing through the heater tube. The
amplified signal times 80 approximates the current flowing through
the heater tube in Amps.
TP16 4-20MA Control signal from computer to vary % power to heater tube. The
HEATER amplifier module (U8) inputs this 0-5VDC control signal and
CONTROL outputs a 4-20mA current signal for the external SCR AL-83193.
The control signal times 20 approximates the % power the SCR
supplies to the heater tube.
TP17 SPARE #1 IN Amplified signal of possible future amplifier module (U9). This
module may measure temperature from a thermocouple or RTD, or
measure a process voltage or current.
TP18 SPARE #2 IN Amplified signal of possible future amplifier module (U10). This
module may measure temperature from a thermocouple or RTD,
measure a process voltage or current, or measure pressure, force or
torque from a strain gage transducer.
Continued
1
Calibration of signals is performed in software by the JFTOT-III application program.


TEST POINTS

TP19 SPARE #3 OUT Control signal to possible future amplifier module (U11). The
module may output a process voltage or current to control another
external device.
TP20 +ECX DP +10.00-VDC excitation output from DP amp module that powers
the DP Transducer.
TP21 +SIG DP Positive signal from DP Transducer input into the DP amp module.
TP22 –ECX DP –10.00 VDC excitation output from DP amp module that powers the
DP Transducer.
TP23 –SIG DP Negative signal from DP Transducer input into the DP amp module.
TP24 +ECX SYS P +10.00-VDC excitation output from System Pressure amp module
that powers the System Pressure Transducer.
TP25 +SIG SYS P Positive signal from System Pressure Transducer input into the
System Pressure amp module.
TP26 –ECX SYS P –10.00 VDC excitation output from System Pressure amp module
that powers the System Pressure Transducer.
TP27 –SIG SYS P Negative signal from System Pressure Transducer input into the
System Pressure amp module.
The components are listed under the “LED” column. The
“Reference” column lists the function and the “Description”
column describes the function. The LED name and the reference
name are located near the component on the PCB.
TABLE 5-20
STATUS LEDS
LED Reference. Color Description

D1 SSR1 Red Digital control signal from computer to activate SSR1 to power the air
pump AL-60113. LED on = pump on.
D2 SSR2 Red Digital control signal from computer to activate SSR2 to enable the
HPLC pump 72020. LED on = enable pump.
D3 SSR3 Red Digital control signal from computer to activate SSR3 to power the
system vent solenoid valve AL-93061. LED on = valve on (open).
D4 SSR4 Red Digital control signal from computer to activate SSR4 to power the dP
+vent solenoid valve AL-93061. LED on = valve on (open).
-vent solenoid valve AL-93061. LED on = valve on (open).
bypass solenoid valve AL-93061. LED on = valve on (open).
D7 SSR7 Red Digital control signal from computer to activate SSR7 to power both
the water pump AL-60119, and activate relay K2 on Power PCB for
heater SCR AL-83193. LED on = power on.
D8 K1 Red Indicates status of watchdog timer. The watchdog timer must receive
a digital control pulse from the computer at least once every 2 seconds,
otherwise the watch times out and turns off, which then turns off the
HPLC pump and the 24V power supply. This status LED must stay
on steady for proper operation of the JFTOT.
D10 PC+5V Green Indicates 5V from computer. This LED must be on before any other
LED can be turned on. LED on = PC 5V on.
Continued

TABLE 5-20
STATUS LEDS (CONTINUED)
LED Reference. Color Description

D11 +24V Green Indicates 24V from external power supply AL-90697. LED on = 24V
on.
D12 +5V Green Indicates 5V from voltage regulator (U12) which powers the 5B
amplifier modules. LED on = 5V on.
Table 5-21 lists the fuses (F1-F9) located on the PC Interface PCB.
The devices protected by the fuse are listed under “References”.
The functions and components controlled by the protected device
are described under “Description”. All fuses on the PCB are 2A
PCB-mount type fuses used to protect the 24VDC circuits on the
PCB. The fuses are installed into receptacles adjacent to the relay
module protected by the fuse.
TABLE 5-21
PC INTERFACE PCB FUSES
Fuse Reference Description

F1 SSR1 Aeration Pump
F2 SSR2 Fuel Drive Pump Enable Line
F3 SSR3 System Vent Solenoid Controlled Valve
F4 SSR4 DP + Vent Solenoid Controlled Valve
F5 SSR5 DP – Vent Solenoid Controlled Valve
F6 SSR6 DP Bypass Solenoid Controlled Valve
F7 SSR7 Bus Heater Relay and Coolant Pump
F8 K1 Base Power Relay K1 on the Power Dist PCB
F9 24VDC Safety Vent Solenoid Valve
Note: All fuses on the PC Interface PCB are rated at 2A (AL-29735)
5.3.7 PRESSURE TRANSDUCER VOLTAGE CHECKS

The pressure transducers (system pressure and differential pressure) are powered by
10.0 VDC. If this voltage is not correct, then the pressure signal output to the
amplifier on the Interface PCB will be in error by the same percentage. If dP
standardization has shown the DP reading to be in error by more than 20%, with no
air in the line, the 10.0 VDC excitation voltage may be incorrect. Measure voltages
on the appropriate connector pins and test points located on the PC Interface PCB,
using a recently calibrated digital voltmeter. Refer to the JFTOT III PC Interface PCB
Layout Drawing in Section 5.9 for pin locations.
NOTE: Refer to pertinent tables and figures in this section for location and
functions of the circuit being tested.
NOTE: See the “Calibration” in Section 4 for calibration procedures.

To measure system pressure only, perform the following steps. Refer to the JFTOT
III PC Interface PCB Layout Drawing in Section 5.9 for pin locations.
1. Before making any measurements, insure the PC is on and running the JFTOT
III program and all three green LEDs (D10, D11, and D12) on the Interface PCB
are fully lighted. See Table 5-20 “Status LEDs”.
2. Measure the +5V voltage that powers the 5B amplifier modules. The voltage
between test points TP3 (+) and TP1 (–) should be 5.00VDC ± 0.20VDC. If
the voltage is not within tolerance, check for short circuits on the PC Interface
PCB and if necessary, replace the PC Interface PCB (AL-54741).
3. The voltage between TP24 (+EXC) and TP26 (–EXC) should be 10.00VDC
± 0.010 VDC. If the voltage is low or high, replace the system pressure
amplifier module (U5).
4. The voltage between TP25 (+SIG) and TP27 (–SIG) should be in the range of
approximately 0.0 to 20mVDC. This voltage is the signal from the pressure
transducer. 0mV = no pressure (0 psig), 20mV = high pressure (500 psig).
5. The voltage on test points TP13 (+) and TP6 (–) should be in a range of
0.0VDC to 5VDC. This voltage is the amplified output signal from the system
pressure amplifier module (U5). For Example: 0.0VDC = no pressure (0 psig),
3.33VDC = high pressure (500 psig).
6. To see if the amplified output signal is correct, use a millivolt source with a low
impedance output, to input a 0-20 millivolt signal.
7. Without disconnecting P3, input the millivolt signal to TP25 (+SIG) and
TP27
(–SIG). Input 0.0mVDC for 0.0 VDC out, and input 20.0mV for 3.33 VDC
out. If readings are not close it may be necessary to replace the system pressure
Perform the following steps to measure differential pressure (DP) only. Refer to the
Drawing in JFTOT III PC Interface PCB Layout Drawing in Section 5.9 for pin
locations.
1. Before making any measurements, insure the PC is on and running the JFTOT
III program and all three green LEDs (D10, D11, and D12) on the Interface PCB
are fully lighted. See Table 5-20 “Status LEDs”.
2. Measure the +5V voltage that powers the 5B amplifier modules. The voltage
between test points TP3 (+) and TP1 (–) should be 5.00VDC ± 0.20VDC. If
the voltage is not within tolerance, check for short circuits on the Interface PCB
and if necessary, replace the Interface PCB (AL-54741).
3. The voltage between TP20 (+EXC) and TP22 (–EXC) should be 10.00VDC
± 0.010 VDC. If the voltage is not within tolerance, it may be necessary to
replace the DP amplifier module (U4).

4. The voltage betweenTP21 (+SIG) and TP23 (–SIG) of connector P4 should be

in the range of about 0 to 20mVDC. This voltage is the signal from the
pressure transducer. 0mV = no pressure (0 mmHg); 20mV = high pressure
(275 mmHg).
5. The voltage between test points TP12 (+) and TP6 (–) should be in a range of
0 VDC. to 5VDC. This voltage is the amplified output signal from the DP
amplifier module (U4). For example: 0.0VDC = no pressure (0 mmHg),
3.33VDC = high pressure (275mmHg).
6. To see if the amplified output signal is correct, use a millivolt source with a low
impedance output, to input a 0-20 millivolt signal.
7. Without disconnecting P4, input the millivolt signal betweenTP21 (+SIG) and
TP23 (–SIG). Input 0.0 mVDC for 0.0 VDC out, and input 20.0mV for 3.33
VDC out. If readings are not close then it may be necessary to replace the DP

5.4 JFTOT III ADJUSTMENTS

Adjustments are sometimes required to ensure the proper values are being
maintained. The adjustment procedures are described in the following subtopics.
5.4.1 ADJUSTING SYSTEM PRESSURE (BACK PRESSURE REGULATOR)

The system pressure is adjusted by changing the settings on the back pressure
regulator shown in Figure 5-85.
The procedure for adjusting the back pressure is listed below.
1. Set up to run a JFTOT III test. (sample in the sample-in container and an
empty container in the sample-out position)
2. Open the left side of the JFTOT III and locate the back-pressure control as
FIGURE 5-85
JFTOT III BACK PRESSURE REGULATOR
Back-Pressure
Control Adjustment
3. Touch or click the MAINT button on the Main Menu and then press or click
the DRV PUMP button on the maintenance screen as shown in Figure 5-86.
FIGURE 5-86
MAINTENANCE MENU
4. Prime the pump if needed. “See Priming the Drive Pump” in subsection 5.4.2.

decremented.
5. Start the drive pump to pump at 3.000 mlpm and wait for the flow to come out
of the sample out line (approximately 20 drops in 9 seconds) in the bus-bar
compartment (See Figure 5-87).
FIGURE 5-87
JFTOT III SAMPLE OUT FLOW
Sample Out Line
NOTE: The drive pump valves may stick occasionally and will need to be cleaned
before the correct flow rate can be obtained. To ensure the correct flow is
obtained, always count the drips coming from the sample out line into the
sample out container. Approximately 20 drops in 9 seconds indicates a flow
of 3 mL/min.
6. Watch the “Sys Pres” indicator (Figure 5-86) and adjust the back-pressure
regulator knob (Figure 5-85) clockwise to increase or counterclockwise to
decrease pressure until the “Sys Pres” indicator reads 500 PSI.
7. Stop the drive pump and vent the system.
8. Replace the cover on the left side of the JFTOT III.
5.4.2 PRIMING THE DRIVE PUMP

The drive pump (Figure 5-88) must be primed when flow cannot reach the set value.
The procedure for priming the drive pump is listed below.
NOTE: It should not be necessary to adjust the controls on the pump itself. Doing so
could cause setting conflicts. Refer to the “Dual Piston Pump Operator’s
Manual” supplied with the JFTOT III for details concerning the drive pump.

1. Set up to run a JFTOT III test. Place a sample in the sample in container and
an empty container in the sample out position.
2. Remove the system pump compartment door on the bottom front left of the
JFTOT III to access the pump as shown in Figure 5-88.
FIGURE 5-88
JFTOT III DRIVE PUMP
Prime/Purge Valve
Output
Dual Inputs
3. Touch or click the MAINT button on the main menu to display the
Maintenance Screen as shown in Figure 5-89.
4. Touch or click the SYS VENT button on the maintenance screen.
5. Touch or click the DRIVE PUMP button on the maintenance screen.
FIGURE 5-89
JFTOT III MAINTENANCE SCREEN
6. Place a napkin or rag under the two pump heads on the drive pump.
7. Double-click inside the FLOW display on the Maintenance screen and then
key in 9.999 into the flow display. Press the ENTER key.
8. Click or touch the DRV PUMP button on the screen to start the pump running
at the 9.999 mlpm flow rate.

FIGURE 5-90
FLOW RATE ENTRY
9. Compress and insert a suction bottle onto the orifice at the center of the knob
on the pump control panel as shown in Figure 5-91.
FIGURE 5-91
SYSTEM PUMP PRIME BUTTON
10. With the compressed suction bottle in place in the prime/purge valve, rotate
the black knob counterclockwise (ccw) until fuel begins to flow out of the
center orifice.
11. Relive pressure on the suction bottle and remove about 20 ml of sample from
the orifice at the center of the knob as shown in Figure 5-92.
FIGURE 5-92
PUMP PRIMING

12. Close the knob and remove the suction bottle. Wait for 9.999 mlpm flow to
come out of the purge out line. The flow at 9.999 mlpm should be very fast
drips (almost a steady stream).
13. Double-click inside the FLOW display on the Maintenance screen, key in
3.000 into the flow display and then press the ENTER key. A 3mlpm flow rate
is about 20 drips in 9 seconds.
14. Clean up any spillage and replace the front cover to the Drive pump
compartment.
NOTE: After the drive pump has been replaced with a new pump or after the pump
has been stored for a period of time, the individual pump heads may need to
be primed directly in order to obtain proper pump output pressure.
5.4.3 ADJUSTING THE SCR

The SCR adjustment for % Power must be performed completely by the operator as a
manual operation.
CAUTION: The SCR adjustment procedure should only be performed by a qualified

service technician. It is possible that a faulty SCR could apply full power to
the bus-bars. If this happens, the heater tube could become very hot
very quickly and melt the tube. The “tube temp” indicator should be
monitored by the operator at all times during this procedure and the “Bus
Heater” should be turned off quickly if the heater-tube temperature is
exceeding 320 deg C.
NOTE: The ideal adjustment provides 60% power when running a D3241 test at
260°C. However, a 260°C D3241 test will run properly with readings of
50% to 80% power. The % power readings at 260°C may differ from 60%
by ± 10% due to variations in line voltage, cleanliness of bus bars (front
and inside connections), and age of JFTOT. The % power reading will be
different for set points and flow rates other than 260°C and 3.0 mL/min
respectively. The SCR output to the heater block and the heater tube can be
adjusted by changing the % power

Perform the following steps to adjust eh SCR heater control.

1. To adjust the SCR, set up to run a JFTOT III test. (sample in the sample-in
container and an empty container in the sample-out position) Ensure the
heater-tube thermocouple is installed and inserted all of the way into the
heater tube.
2. Open the right side of the JFTOT III and locate the SCR heater control as
FIGURE 5-93
SCR HEATER CONTROL LOCATION
SCR Heater Control
3. Touch or click the MAINT button on the Main Menu and then press or click
the DRV PUMP button on the maintenance screen as shown in Figure 5-94.
FIGURE 5-94
MAINTENANCE MENU – DRIVE PUMP ON
decremented.

4. Start the drive pump to pump at 3.000 mlpm and wait for the system pressure
to reach near 500 psi and flow to come out of the sample-out line in the bus-
bar compartment. Prime the pump if needed. (See “Priming the Drive Pump”
in Section 5.4.2)
NOTE: The drive pump valves may stick occasionally and will need to be cleaned
before the correct flow rate can be obtained. To ensure the correct flow is
obtained, always count the drips coming from the sample out line into the
sample out container. Approximately 20 drops in 9 seconds indicates a flow
of 3 mlpm.
5. Enter a value of “15” into the %PWR control and touch or click the BUS
HEATER button as shown in Figure 5-95. The coolant pump should start.
6. Adjust the coolant flow-meter to the green area.
FIGURE 5-95
JFTOT III BUS-HEATER CONTROL
CAUTION: There is about a 20 second soft-start built into the SCR so do not try to
adjust anything for 20 seconds.
7. Using a small jewelers screwdriver carefully adjust the “BIAS” control on the
SCR (Figure 5-96) until there is a reading of 0.005 indicated in the “Volts”
indicator.

FIGURE 5-96
JFTOT III BUS HEATER CONTROL BIAS ADJUSTMENT
BIAS Adjustment
8. Slowly increase the value in the %PWR button (Figure 5-89) in 10%
increments while watching the heater tube temperature. If the temperature
gets above 260°C then turn down the “GAIN” control on the SCR (Figure 5-
97). Continue increasing the %pwr while watching the temperature and
turning down the “GAIN” control as necessary until the value in the “%pwr”
control is 60% and the heater-tube temperature is 260°C.
FIGURE 5-97
JFTOT III BUS HEATER CONTROL GAIN ADJUSTMENT
GAIN Adjustment
NOTE: Because the BIAS and the GAIN control affect each other, this procedure
may have to be repeated several times. The goal is to have the “volts”
indicator read 0.005 when 15% power is applied and the heater-tube
temperature read 260°C when 60% power is applied. Enough time must be
allowed for the system to become thermally stable after applying 60%
power.
5.4.4 ADJUSTING THE 5-VDC RH REFERENCE VOLTAGE

After the PC Interface PCB has been replaced, the 5VDC reference for the RH sensor
must be adjusted. When necessary, adjust the amplifier on the PC Interface PCB for
+5.00 VDC as follows:
1. Remove the panel on the left-hand side of the JFTOT.

WARNING: A potentially lethal electrical shock hazard exists when contact is made with
the 115/230-Volt line components.
2. Power up the JFTOT.

3. Locate the test points TP5 and TP 6 on the left edge of the PC Interface PCB as
FIGURE 5-98
RH REFERENCE VOLTAGE ADJUSTMENT
5 VDC Adjust (R4)
TP5 TP6
4. Connect the + and – leads of a voltmeter to TP5 and TP6 respectively.

5. Check the voltage reading for +5.00 VDC.
6 If the reading is above or below +5.00 VDC, adjust trimpot R4 (Figure 5-98)
to obtain a reading of +5.00 VDC.
7. Remove the meter leads and install the side panel.
5.4.5 POWER ENTRY MODULE FUSE CONFIGURATION

Check the power entry module for correct 115/230VAC orientation as required for
the available power receptacles. Either 115V or 230V should show in the module
window. If not oriented correctly, refer to subsection 5.4.5.1 or subsection 5.4.5.2
below.
NOTE: For 115 VAC use one 8A-3AG, Fast (PN: AL-29686) and a shorting clip.
If metal shorting clip is not available, install an 8A Fuse in both sides of the
holder. For 230 VAC use two 6.3A, 5x20mm SB (PN: AL-29738) without the
shorting clip.
5.4.5.1 Power Entry Fuse Reconfiguration (115VAC to 230VAC)

Use the following procedure to change the power-entry module
from 115 VAC to 230 VAC.
1. Use a small, flat-blade screwdriver to pry up the latch on the
module as shown in Figure 5-99A.
2. Use a small, flat-blade screwdriver to pry out the module as
shown in Figure 5-99B and then remove the module as shown
in Figure 5-99C.

FIGURE 5-99
115-VAC POWER ENTRY MODULE REMOVAL
A B C
3. Remove the 115VAC fuse as shown in Figure 5-100A.

4. On the opposite side, remove the metal shorting clip from the
rear of the module as shown in Figure 5-100B.
FIGURE 5-100
115-VAC FUSE AND SHORTING CLIP REMOVAL
A B
5. Install a 6.3-A, 250-VAC SB fuse at the rear of the holder (opposite the
panel end) in both sides of the module as shown in Figures 5-101A
and 5-101B.
FIGURE 5-101
230-VAC FUSE INSTALLATIONS
A B

6. Reinstall the module with the 230V label on top as shown in

Figure 5-102A. Ensure the fuse module snaps all the way into the
housing as shown in Figure 5-102B.
7. Snap the latch back into place over the module and check the window for
the correctly labeled voltage (230V) as shown in Figure 5-102C.
FIGURE 5-102
230-VAC POWER ENTRY MODULE INSTALLATION
A B C
5.4.5.2 Power Entry Fuse Reconfiguration (230VAC to 115VAC)

Use the following procedure to change the power-entry module
from 230 VAC to 115 VAC.
1. Use a small, flat-blade screwdriver to pry up the latch on the
module as shown in Figure 5-103A.
2. Use a small, flat-blade screwdriver to pry out the module as
shown in Figure 5-103B and then remove the module as
shown in Figure 5-103C.
FIGURE 5-103
230VAC POWER ENTRY MODULE REMOVAL
A B C
3. Remove the two 230 VAC fuses as shown in Figure 5-104A

and Figure 5-104B.

FIGURE 5-104
230VAC FUSE REMOVAL
A B
4. With the fuse holder oriented with the 115V label up, install an 8A fuse
into the right-hand side of the holder as shown in Figure 5-105A.
5. Install the metal shorting clip at the rear on the opposite side of the
holder as shown in Figure5-105B. If the metal shorting clip is not
available, install an 8-A fuse in both sides of the holder.
FIGURE 5-105
115-VAC FUSE AND SHORTING CLIP INSTALLATIONS
A B
6. Reinstall the module with the 115V label on top as shown in

Figure 5-106A. Ensure the fuse module snaps all the way into the
housing as shown in Figure 5-106B.
7. Snap the latch back into place over the module and check the window for
the correctly labeled voltage (115V) as shown in Figure 5-106C.
FIGURE 5-106
115VAC POWER ENTRY MODULE INSTALLATION
A B C

5.5 SOFTWARE INSTALLATION

The following procedures can be used to reinstall the JFTOT III software or to install
new versions of the software for the JFTOT III.
5.5.1 MS WINDOWS XP PROFESSIONAL OS INSTALLATION

Microsoft Windows XP Professional OS software is installed and tested before
shipment and should not need to be reinstalled by the user. If it becomes necessary to
reinstall the Windows OS software, the user will need to connect a CD ROM Drive,
VGA Monitor, keyboard and mouse to the JFTOT III computer in order to reinstall the
OS from the Microsoft Windows XP Professional OS installation CD provided with the
analyzer.
After installing the CD containing the MS Windows XP Professional OS software,
follow the prompts to reinstall the OS software. If problems arise during or after the
installation contact the PAC Service department.
5.5.2 NI-DAQ SOFTWARE INSTALLATION

The NIDAQ Software was installed and configured in the JFTOT III at the factory
before shipment and should not need to be reinstalled and configured unless the
computer or DAQ board has been replaced. Before the computer is installed into the
JFTOT III, the required software and hardware need to be installed onto the
computer. Because the DAQ board is a 6024E it will require NI-DAQ 7.2
(Traditional NI-DAQ). NI-DAQ-7 is a two-CD set labeled Disk 1 of 2 and Disk 2 of 2.
If it becomes necessary to reinstall the NIDAQ software, perform the following steps.
1. Attach the power cable, keyboard and mouse to the computer.
2. Switch on the computer power switch and press the momentary switch that is
attached to the computer on a 12” cable.
3. Wait for the computer to power up and finish loading Windows XP.
4. Insert the NI-DAQ CD labeled Disk 1 of 2 into the CD player on the right side
of the computer. The following menu (Figure 5-107) will appear.
FIGURE 5-107
OPTIONS MENU SCREEN

5. Click on the “Install NI-DAQ / NI-SWITCH” option. A product information

screen will appear as shown in Figure 5-108.
FIGURE 5-108
PRODUCT INFORMATION SCREEN
6. Click the NEXT >> button as shown in Figure 5-108.

7. A Destination window will appear. Click the NEXT button as shown in
Figure 5-109.
FIGURE 5-109
DESTINATION WINDOW
8. A window will appear (Figure 5-110) that allows you to select the features you
want to install and where you want to install them. Click the NEXT >>
button to install all of the features in the C:\Progran Files\National
Instruments\NI-DAQ\ folder.

FIGURE 5-110
NI-DAQ FEATURES SCREEN
9. A license agreement (Figure 5-111) will appear. Click on the round “I Accept
the License Agreements” button to accept the agreement.
10. Click the NEXT >> button as shown in Figure 5-111.

FIGURE 5-111
LICENSE AGREEMENT SCREEN
11. A second License Agreement will appear (Figure 5-112). Click “I Accept the
License Agreements” and click NEXT >>.

FIGURE 5-112
SECOND LICENSE AGREEMENT SCREEN
12. The Start Installation window (Figure 5-113) will appear. Click NEXT >> to
proceed with the installation.
FIGURE 5-113
START INSTALLATION WINDOW
13. The Overall Progress indicator (Figure 5-114) will be displayed. Allow the
installation to continue until prompted to install the second CD.

FIGURE 5-114
OVERALL PROGRESS SCREEN
14. When the Insert Source window prompts you (Figure 5-115), remove the CD
labeled Disk 1 of 2 and insert the CD labeled Disk 2 of 2.
15. If the installation does not resume on its own, then click the RESCAN DRIVE
button (Figure 5-115) to continue the installation.
FIGURE 5-115
INSERT SOURCE SCREEN
16. The installation will continue until it is complete. When the Installation
Complete window (Figure 5-116) is displayed, click FINISH.

FIGURE 5-116
INSTALLATION COMPLETE WINDOW
17. You will be prompted to restart the computer as shown in Figure 5-117.
FIGURE 5-117
RESTART COMPUTER SCREEN
18. Click the SHUT DOWN button to turn off the computer and get ready to install
the data acquisition hardware.
5.5.3 JFTOT III APPLICATION SOFTWARE INSTALLATION

The JFTOT III software was installed in the JFTOT III at the factory before
shipment and should not need to be reinstalled and configured unless the computer
or DAQ board has been replaced. After the computer and DAQ board and related
software (See 6024E DAQ PCI Board Configuration in Section 5.3.6.4) have been
installed into the JFTOT III, the latest version of the JFTOT III software needs to be
installed onto the computer.
To reinstall the JFTOT III application software, perform the following steps.
1. From the MS Windows desktop, click the START button on the taskbar and
click the “Control Panel” icon as shown in Figure 5-118.

FIGURE 5-118
OPTIONS SCREEN
2. From the Control Panel, double-click the “Add or Remove Programs” icon
FIGURE 5-119
CONTROL PANEL SCREEN
3. From the Add or Remove Program Screen, click on the “Add New
Programs” icon as shown in Figure 5-120.
4. Click on the CD OR FLOPPY button as shown in Figure 5-120. A window will
appear (Figure 5-121) and prompt you to install the program CD into the
CD drive.

FIGURE 5-120
ADD OR REMOVE PROGRAMS SCREEN
5. Put the JFTOT III software CD into the CD drive and click the NEXT button
FIGURE 5-121
INSTALL PROGRAM SCREEN
6. The computer will look on the CD for the installation program. It should find
the file D:\setup.exe. Click the FINISH button as shown in Figure 5-122.

FIGURE 5-122
RUN INSTALLATION PROGRAM SCREEN
7. A prompt window will appear to prompt for a destination directory to install

the program. To use the default directory displayed in the Destination Folder
area, click the NEXT button as shown in Figure 5-123.
FIGURE 5-123
JFTOT III VER 2 SETUPSCREEN – DESTINATION FOLDER
8. The JFTOT III Installation Wizard Welcome window will appear. Click the
NEXT button as shown in Figure 5-124 to start the installation.

FIGURE 5-124
INSTALLATION WIZARD WELCOME SCREEN
9. The JFTOT III Software installation will start running and the status screen
will be displayed as shown in Figure 5-125.
FIGURE 5-125
JFTOT III UPDATING SYSTEM STATUS BAR
10. Do not click on anything. Wait until the installation is complete.

11. When the following window appears (Figure 5-126), click the FINISH button.

FIGURE 5-126
JFTOT III VER 2 INSTALLED SUCCESSFULLY SCREEN
The JFTOT III Software has been successfully installed.

To create a shortcut icon to place on the desktop proceed as follows:
1. From the MS Windows Desktop, click the START button and select the “All
Programs” option as shown in Figure 5-127.
2. Locate the JFTOT III program on the programs option display and right-click
the JFTOT III icon as shown in Figure 5-127.
3. Click on the “Create Shortcut” option (Figure 5-127) and drag the shortcut
onto the computer MS Windows desktop.
FIGURE 5-127
JFTOT III CREATE SHORTCUT SCREEN

5.6 ERROR MESSAGES

Software control parameters allow the user to be assured that instrument parameters
are nominal before beginning analysis. Deviations from these expected conditions
result in “Error Message” that must be resolved before the instrument run sequence
can be initiated. Instrument Hardware Error messages and the actions required to
correct them are listed below.
TABLE 5-22
ERROR MESSAGES
Message Possible Cause Required Action

“ERROR: The Dri-Rite crystals need to be 1. Color of Dri-Rite crystals is 1. Replace with new blue Dri-Rite
changed. Restart the test after the crystals changing from blue to pink due and then Restart the test.
have been changed. to moisture.
“ERROR: Temperature varied by more 1. Cover removed from test area 1. Reinstall cover over test area.
than 2% allowing drafts across test
section
2. SSR gain set too high 2. Readjust SCR (Sec 5.4.3).
“ERROR: Failed to Pressure to 475 – 550 1. Air in fuel system 1. Re-run test..
psi (+/– 10% = 475-575) within 1 minute 2. Leak in fuel system 2. Check for air and fuel leaks.
“ERROR: Fuel Temperature Too Cold JFTOT III Shuts Down 1. Check settings
(<15°C) 2. Determine cause for low temp.
3. Restart JFTOT
“ERROR: Fuel Temperature Too Hot JFTOT III Shuts Down 1. Check settings
(>30°C) 2. Determine cause for low temp.
3. Restart JFTOT
“ERROR: Heater Tube Resistance Out of 1. Bus-Bar Clamps are too loose 1. Tighten bus-bar screws
Tolerance 2. Heater Tube out of spec. 2. Replace Heater Tube
“ERROR: Thermocouple not responding 1. Thermocouple not in tube 1. Clamp thermocouple into place.
correctly correctly
2. Thermocouple defective 2. Replace Thermocouple.

5.7 TROUBLESHOOTING GUIDE

This section is a guide provided to aid in isolating and correcting problems that may
arise while operating the analyzer. To use this guide, simply locate the symptom in
the left column and follow suggestions for probable cause and remedy.
For detailed drawings of component location, electronic schematics, flow diagrams,
parts lists, and servicing guidelines, refer to “Drawings” at the back of this manual.
5.7.1 ELECTRICAL/ELECTRONIC COMPONENT REPLACEMENT

1. Before attempting to perform any troubleshooting and before taking any action
to remedy an apparent problem, ensure that all components of the analytical
system and any accessories are properly assembled.
CAUTION: Many of the components used in the electronic subassemblies can be

damaged due to electrostatic discharges. Always wear a grounded, static-
prevention wrist strap when working with electronic parts and assemblies.
2. In the event an electrical or electronic component needs replacement, the

following steps should be taken.
3. Switch the external AC power switch and the analyzer main power switch to
the OFF position.
servicing internal components. Ensure that the power is removed from the
power source before continuing.
4. Locate the electrical or electronic component to be replaced, and carefully

remove any interconnecting wiring noting its location.
5. Carefully, replace the defective electrical or electronic component with a

new one.
6. Carefully, replace and secure any detached interconnecting wiring.
7. Perform the startup procedure and a sample analysis to confirm proper
operation of the new electrical or electronic component.
8. Resume normal operation.

5.7.2 TROUBLESHOOTING GUIDE

TABLE 5-23
TROUBLESHOOTING GUIDE
Symptom Probable Cause Corrective Action

1. Auto Cal Temperatures are 1. Contaminated Lead Std 1. Replace Lead
incorrect 2. Probe not in center of lead 2. Center probe
2. Embedded Computer not running 1. Blown Fuse 1. Check fuse and replace if
defective.
2. Defective Computer 2. Replace embedded computer
PCB.
3. Differential pressure buildup and 1. Plugged Line in System 1. Back flush the lines one at a time
shutdown while in the Setup Mode 2. DP filter is plugged 2. Replace DP Filter
5. Heater setpoint cannot be reached 1. Bus Bar contacts corroded or dirty 1. Clean contact surfaces with a soft
2. Bus-Bar power cable corroded gum eraser (n-heptane can be
3. Heater Power Controller is out of used as a cleaning solvent)
adjustment 2. Use a mild abrasive to clean away
4. Tube shorted to test section corrosion and deposits. Ensure
power cables are making good
contact with the bus bars.
3. Adjust SCR only as a last resort.
4. Ensure tube is not bent and
ceramic bushings are in place and
not broken.
6. Leaks in heater test section 1. Seal leakage 1. Tighten (finger tight) or replace
seal
7. Leaks in lines and fittings 1. Seal leakage 1. Replace o-ring
8. No Air flow when aerator is turned 1. Air flow control valve closed 1. Open valve and adjust flow to
on 2. Tubing loose from fitting green range
3. Air pump failure 2. Reconnect tubing
4. Fuse F1 on PC Interface PCB 3. Replace pump
4. Replace Fuse F1 on PC Interface
PCB
9. Failure to obtain correct 1. Failure to follow procedures 1. Read and follow all calibration
Calibration Temperature 2. Lead Standard Contaminated instructions.
3. Defective Thermocouple 2. Replace Lead Standard.
4. PC needs adjusting 3. Replace Thermocouple
4. Contact PAC Service Dept.
10. Watts reading causing Test to 1. Heater tube not clamped tight in 1. Retighten bus bars
Abort bus bars
2. Heater tube ID or OD out of 2. Replace heater tube
tolerance
3. Heater tube material not as 3. Replace heater tube
specified
4. Heater tube used previously at 4. Replace heater tube
high temp
5. Heater tube is shorted to the 5. Remove short or replace tube
heater test section 6. Adjust flow meter
6. Improper flow
Continued

TABLE 5-23
TROUBLESHOOTING GUIDE (CONT.)
Symptom Probable Cause Corrective Action

11. Heater tube resistance causing 1. Heater tube not clamped tight in 1. Retighten bus bars
Test to Abort bus bars
2. Heater tube ID or OD out of 2. Replace heater tube
tolerance
3. Heater tube is shorted to the 3. Remove short or replace tube
heater test section 4. Replace heater tube
4. Heater tube used previously at
high temp
12. Unable to obtain proper aeration 1. Obstructed tubing, filter, dryer or 1. Clear obstruction
flow adjustment aeration tube
13. Unable to obtain proper coolant 1. Coolant level low 1. Fill coolant container to half full
flow 2. Obstructed tubing, bus bar, with 50% water and 50% coolant
radiator or jet tube position 2. Remove obstruction or reposition
3. Defective water pump jet tube inside bus bar
3. Replace water pump
14. % Power increases over time 1. Corrosion build up on bus bars 1. Clean bus bars and end caps
15. Sample fuel flow rate low, erratic, 1. Air in lines 1. Perform purge procedure
or stopped 2. Sample Pump needs priming 2. Perform priming procedure
3. Fuel clog 3. Remove pump heads and flush
with fuel
16. Solenoid valves will not operate 1. Loose Wire or bad connection 1. Check wire connections
2. Blown fuse on Interface PCB 2. Replace fuse
17. Heater SCR, Water Pump, and 1. Blown F7 fuse on Interface PCB 1. Replace fuse
Fan 2 will not turn on
18. Drive Pump Will Not Run 1. Blown F2 fuse on Interface PCB 1. Replace fuse
19. JFTOT III Program running but 1. Blown fuse on 24VDC Power 1. Replace fuse
nothing else will turn on. Supply
2. Cable between PC and Interface 2. Reconnect cable
PCB is disconnected
3. Blown Fuse 8 on PC Interface 3. Replace fuse
PCB

5.8 SPARES, ACCESSORIES, SUPPLIES, AND MATERIALS

The following list describes the supplies, materials, spares and accessories that can be
obtained for the JFTOT III by placing an order to ALCOR. As specified in Section 2
“Installation”, many items are provided with the JFTOT III. Sufficient quantities of
most spares and supplies are provided with the JFTOT III to run 20 tests. However,
other items are not provided with the JFTOT III but are required for normal
operation.
The following items are required to be replaced after each test and therefore must be
stocked in accordance with the volume of testing involved:
• Heater tube and filter kit - AL-91652 (Box of 10)

• Pre-filter kit – AL-38057 (Box of 25)
• General-purpose, retentive, qualitative filter paper - AL-27052 (Box of 100)
Spare Parts for the JFTOT III are listed in the following table.
TABLE 5-24
JFTOT III SPARE PARTS LIST
# ITEM PART NO
1 Cable, USB Panel-Mount Extension 16461

2 Cable, PS2 Panel-Mount Extension 16462
3 Cable, Cat 5e Patch with RJ45, 3 ft. 16463
4 Cable, NIDAQ to Interface, JFTOT-III 16465
5 Filter, Charcoal, .75” x 3.75” x 10.625” 16991
6 Fuse, 0.75 Amp Time-Delay, 3AG ¼” x 1-¼” 289034
7 Fuse, 0.5 Amp Fast, 3AG ¼” x 1-¼” 289036
8 Union Bulkhead, SS 1/8” 30045
9 Tubing, Teflon, 1/8” 30066
10 Quick Connect Bulkhead Body, 1/8”, Black 30765
11 Quick Connect Bulkhead Body, 1/8”, Green 30766
12 Quick Connect Stem, 1/8”, Black 30768
13 Quick Connect Stem, 1/8”, Green 30770
14 Computer, Pentium, Industrial Touch Screen 32202
15 Amplifier Input Module, 0-500C type K T/C 45276
16 Amplifier Input Module, 0-1V True RMS 45277
17 Amplifier Input Module, 0-5A True RMS 45278
18 Amplifier Output Module, 4-20mA 45279
19 Relay Module, Watchdog Timer, 2 Sec. 45280
20 Relay, Solid State 240V 25A 50003
21 Fan, 4”, 120VAC 61009-115V
22 Hinge, 737 61028
Continued

TABLE 5-24
JFTOT III SPARE PARTS LIST (CONT)
# ITEM PART NO
23 Hinge, Test Section Cover 61069
24 Glass Sample Beaker 68019
25 Scrubber, Dririte for Aeration (Includes Dririte) 71283
26 Pump, HPLC Series 1500, Self Flush 72020
27 Power Entry Module, IEC plug/Fuse/Switch 80085
28 Clamp, Plastic 1.25” ID (Water Pump Mount) 83234
29 Jack, RJ45 Cat 5e In-Line Modular 84351
30 Sensor, Humidity, 1/8” tube ends 92243
31 Power cord, European 230V 97107-1
32 Power cord, UK 230V 97107-2
33 Tube, Cooling Jet AL-10831
34 Plate, Bus Bar Mounting, JFTOT-III AL-10835
35 Bus Bar Assembly, JFTOT-III (2 required) AL-10836
36 Insulator Bushing Kit AL-11926
37 Cover, Sample Vessels, JFTOT-III AL-13227
38 Cover, Heated Test Section, JFTOT-III AL-13228
39 Bottle, Water Reservoir, JFTOT-III AL-17683
40 Jack, Type K T/C, Female Panel Mount AL-23863
41 Amplifier Input Module, Strain Gage AL-24638
42 Backup Screen, Pre-Filter AL-27051
43 Prefilter Assembly AL-27075
44 Filter, Inlet, 10um, SS 1/8” AL-27096
45 Fitting, Cooling Jet AL-28389
46 Fitting, Inlet Filter (for AL-27096) AL-28432
47 Fuse, 8A Fast 3AG ¼” x 1-¼“ AL-29686
48 Fuse, 6.3 A SB 5mm x 20mm AL-29738
49 Fuse, 2A, PCB Mount AL-29735
50 Fuse, 4A Fast 3AG ¼” x 1-¼” AL-29736
51 Fuse, 1.5A Fast 3AC 1/4:” x 1-¼” AL-29737
52 Heater Test Section Housing, JFTOT AL-35291
53 AutoCal Heater Assembly, Lead, JFTOT-III AL-35387
54 Differential Pressure Transducer AL-45042
55 System Pressure Transducer, 500psi AL-45043
56 Tubing, Teflon, ¼” OD x .047” wall AL-49291
57 Tubing, 5/16” OD x .063 wall AL-49292
58 Interface PCB Assembly, JFTOT-III AL-54741
59 O-Ring, Line Connector (25 per pack) AL-53706
Continued

TABLE 5-24
JFTOT III SPARE PARTS LIST (CONT)
# ITEM PART NO
60 O-Ring, Prefilter AL-54708

61 Power PCB Assembly, JFTOT-III AL-54743
62 PCB, NIDAQ to Interface PCB, JFTOT-III AL-54744
63 Flowmeter, Water, JFTOT-III AL-58036
64 Flowmeter, Air, JFTOT-III AL-58037
65 Air Pump Assembly, 24VDC AL-60113
66 Water Gear Pump, Miniature 24VDC AL-60119
67 Radiator, Heat Exchanger AL-60684
68 Regulator, Back Pressure AL-61637
69 Solid State Relay, DC Output Module AL-62461
70 Screw, Bus-Bar Clamp AL-66661
71 Calibration Standard Lead (package of 10) AL-72132
72 Spring, .210 OD x .158 ID x .022 D, SS AL-75212
73 SCR Power Control, DIN-A-MITE, 120VAC AL-83193
74 T/C Type K, Sample Vessel, JFTOT-III AL-86301
75 T/C Type K, Bus Bar, JFTOT-III AL-86302
76 T/C Type K, Heater Tube, JFTOT-III AL-86303
77 Power Supply, 24VDC, 2.4A AL-90697
78 Transformer, 1KVA Step-Down AL-90698
79 Current Transformer, 400:5 AL-90720
80 Transformer, Low-Voltage, 115VAC AL-90719
81 Solenoid, 24VDC SS NC 1/4NPT 500psi AL-93061
82 Solenoid, 24VDC SS NO 1/4NPT 500psi AL-93062
83 Check Valve, 7psi, 1/8”FNPT, PVC AL-93109
84 Power cord, US 120V AL-97072
85 Power Cable with Ring Terminals AL-97139

TABLE 5-25
JFTOT III SUPPLED SPARE PARTS
# Qty Item Part No

1 5 Fuse, 0.5 A packs 289036
2 5 Fuse, 8 A AL-29686
3 10 Fuses, 4 A AL-29736
4 5 Fuses, 0.75 A 289034

Pre-Filters Kit (25 Filter Elements per kit), Plug 1backup screen, 1
5 1 AL-38057
O-Ring
6 1 O-Ring Packs (25 O-rings per Pack) AL-35706
7 2 Heater Tube Insulator Packs (4 per Pack) AL-11926
8 5 Fuse, 1.5A AL-29737
9 10 Fuse, 2A, PCB AL-29735
10 10 Fuse, 6.3A, SB 5x20mm (for 230VAC) AL-20738
11 2 Boxes, Heater Tube and Filter Kits (10 per box) AL-91652
TABLE 5-26
JFTOT III ACCESSORIES
# Qty Item Part No

1 1 Bottle and Tube Assembly (verify dP) AL-37633
2 1 Brush, ¼” x 2” AL-09970
3 1 Calibration Standard (Lead) (7.2g) AL-72132
4 1 Pre-Filter Kit (25 Elements) AL-38057
5 1 Cleaning Pan, SS AL-38012
6 1 Tray, Sample Vessel Holder AL-08214
7 1 Tray, Test Section Overflow AL-08217
8 1 Disposable Gloves, Box AL-83033
9 1 Rubber Squeeze Bulb AL-38010
10 1 Tweezers AL-38009
11 1 Hex Driver, 5/32” AL-38016
12 1 Extractor, Insulator AL-38017
13 2 Wash Bottle AL-38013

TABLE 5-26
JFTOT III MATERIALS
# Item Part No
1 Aluminum Foil AL-38008
2 Paper Tissue, Box AL-89034
3 Silicone Grease AL-38018
4 Filter Paper (Box of 100) AL-27052
5 Dri-rite Refill Kit (1 lb) 71028
6 Coolant, Anti-Freeze AL-73140
The following additional items are not supplied with the JFTOT III but are required
for normal operation:
• ALCOR Visual Tuberator: The ALCOR Visual Tuberator (AL-85417, 115VAC
and 85418, 230 VAC) is required for determining the results of the JFTOT III
tests but must be ordered as a separate item.
• Solvent; may be technical grades of n-heptane, or 2,2,4-trimethyl pentane

technical grade (95 mol percent minimum purity)
• Trisolvent (equal parts of toluene, acetone, and isopropyl alcohol, 99% grade)
• Thermometer, glass (ASTM 1C, 5C, or IPIC)

• Bulbs for tuberators, 30 W incandescent reflective type
TABLE 5-28
JFTOT III OPTIONAL EQUIPMENT
# Item Part No
1 Line Voltage Conditioner, 120 VAC AL-90714

5.9 DRAWINGS
The following drawings are provided for reference during the performance of
maintenance and service functions described in the previous subsections.
TABLE 5-29
JFTOT III DRAWINGS
# Drawing
1 JFTOT III Power Distribution PCB Layout Drawing ( Dwg No. 54743 Rev A)
2 JFTOT III Power Distribution PCB Schematic ( Dwg No. 64990 Rev A)
3 JFTOT III PC Interface PCB Layout Drawing( Dwg No. 54741 Rev A)
4 JFTOT III PC Interface PCB Schematic ( Dwg No. 54989 Rev A)
5 JFTOT III Schematic( Dwg No. 64991 Rev B)
6 JFTOT III Block Diagram (Dwg No. 85436 Rev A)
7 JFTOT III Flow Diagrams

















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JFTOT 230

8824 Fallbrook Dr. • HOUSTON, TEXAS 77064 USA

Copyright ©2006, by PAC, Houston, Texas.

STANDARD LIMITED WARRANTY.......................................................................................... v

SECTION 5: MAINTENANCE AND SERVICE

File Name: JFTOT III User’s Manual Part No. 59322

ABOUT THIS MANUAL

A Quick-Start Guide is included in Section 3 “Operation” and is provided as a laminated

This symbol (exclamation point in a triangle) indicates a general Caution or

This symbol (a lightning bolt in a triangle) indicates an electrical shock hazard.

PROTECTIVE GROUND CONDUCTOR: indicates earth ground wire or

DP DIFFERENTIAL PRESSURE (DP): indicates pressure across the filter (reported in

Part No. 59322 File Name: JFTOT III User’s Manual

ABBREVIATIONS AND SYMBOLS

File Name: JFTOT III User’s Manual Part No. 59322

PROPER USE AND SAFETY

Part No. 59322 File Name: JFTOT III User’s Manual

STANDARD LIMITED WARRANTY

File Name: JFTOT III User’s Manual Part No. 59322

II. Limitations on PAC Liability

PAC • 8824 Fallbrook Dr. • Houston, Texas • 77064 • USA

Part No. 59322 File Name: JFTOT III User’s Manual

Warranty Registration Certificate Form

Customer Name Phone Number

Mailing Address Fax Number

File Name: JFTOT III User’s Manual Part No. 59322

8824 Fallbrook Dr. • HOUSTON, TEXAS 77064 USA

Copyright ©2006, by PAC, Houston, Texas.

SECTION 1: TABLE OF CONTENTS

File Name: JFTOT III User’s Manual Part No. AL-59322

1.1.1 BENEFITS AND FEATURES

Part No. AL-59322 File Name: JFTOT III User’s Manual

1.1.2 Specifications (Continued)

1.1.3 AVAILABLE CERTIFICATIONS

1.1.5 OTHER REQUIRED EQUIPMENT

2 Printer with USB interface (USA only) or user-supplied printer

File Name: JFTOT III User’s Manual Part No. AL-59322

1.1.6 SOFTWARE OVERVIEW

NOTE: The standard MS Windows® XP Professional® screens displayed should be

Part No. AL-59322 File Name: JFTOT III User’s Manual

1.1.7 JFTOT III SIMPLIFIED BLOCK DIAGRAM

Touch Screen LCD

Microsoft Windows XP Professional OS

Data Acquisition PCB (DAQ)

Sample Sample Sample Sample

Deposit Collection Tube Sample Delivery System

File Name: JFTOT III User’s Manual Part No. AL-59322

1.2 FUNCTIONAL OVERVIEW

User I/O 115VAC 115VAC To

24VDC From Comp IF PCB

Aerated Sample Coolant Air

Part No. AL-59322 File Name: JFTOT III User’s Manual

1.3 THEORY OF OPERATION

File Name: JFTOT III User’s Manual Part No. AL-59322

1.4 COMPONENT DESCRIPTIONS

1.4.1 FRONT PANEL

Sample Test Area

1.4.1.1 Sample Container Area

Part No. AL-59322 File Name: JFTOT III User’s Manual

Sample-In Tube Vent Out Line

1.4.1.2 Heater Tube Test Area

Air Flowmeter Coolant Flowmeter

Upper Bus Bar

Heater Tube + DP Port (Out)