Maintenance, Calibration & Repair of Engineering Systems Testing Machines
Engineering Systems provide calibration, servicing, and repair services for all our current and discontinued products. Depending on usage and application, we would recommend that machines are calibrated every 6 - 12 months, and serviced anually. Calibration can be carried out at our factory using traceable dead-weight loading equipment. Alteratively should customers wish to carry out calibration themselves, weights & proving rings are available to purchase - please contact us for details.
This page contains some maintenance and toubleshooting information for our products. Please contact us before carrying out repairs or maintenance if you are in any doubt. Please also contact us before returning machines, as simple faults can often be rectified without the need for a return. Please have the serial number of the machine to hand when contacting us.
Product History
- The C53 has been in production since 2007, to the present.
- The CT6 has been in production since 2008, to the present.
- The CK10 was introduced in 1995 and is currently out of production.
- The C50 was in production from 1992 to 2006, and was replaced by the C53.
- The CT5 was in production from 1992 to 2007, and was replaced by the CT6.
- The ET500 was in production from 1990 to 1994.
- The C40 was in production from 1985 to 1992.
- The CT40 was in production from 1978 to 1991.
Maintenance, Calibration & Repair of the C53 and the CT6
Loading C53 paper - step 1
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Loading C53 paper - step 2
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Maintenance & calibration instructions for these machines can be found in the handbook, available to download
here. Depending on usage and application, we would recommend that machines are calibrated every 6 - 12 months and serviced annually.
Calibration can be carried out using the appropriate calibration kit or proving ring, or the machine can be returned to us for calibration
and / or servicing.
Firmware Updates: Firmware in both the C53 & CT6 can be updated via a USB or RS232 connection to a PC. We recommend updating C53 machines running firmware older than V1.15 and CT6 machines with firmware older than V2.09. Newer firmware adds additional features and resolves a small number of problems found in previous versions. Further details of how to update the firmware can be found here.
Troubleshooting information can be found in the handbook. Solutions to some common problems include: -
Printer doesn't work, or feeds blank paper: Check that the printer is enabled in the setup menu, and that there is paper in the printer.
Ensure that thermal paper is used - the paper used in older Engineering Systems machines is not suitable.
Check
that the paper is inserted in the correct orientation (as illustrated here for the C53), as thermal paper will only print on one side. See the sticker inside
the paper compartment or the handbook for instructions.
Time & date are incorrect, or 'Results Data Lost' is shown at switch-on: Reset the time & date via the setup menu. If the problem continues, remove the bottom cover and replace the CR1616 lithium coin cell on the main circuit board.
Repair status for the C50
As of 2014, we intend to continue to repair these wherever possible. However, a number of parts are starting to become difficult to obtain or obsolete, so we cannot guarantee that all faults can be repaired.
Some repairs which may be necessary for older machines are:-
The Display is stuck showing 8888 and the machine will not start up:
Switch off the printer and restart the
machine. If it now starts up correctly then the printer is faulty. Contact Engineering Systems for printer repair / replacement.
This also applies to the CT5. If the problem continues, check all the fuses, and try disconnecting the printer.
The fault can be caused by a number of problems, so if it still cannot be found contact Engineering Systems for advice.
Printer will not print:
Either the printer electronics or the mechanism have stopped working.
Cure: Fit a new printer, or a reconditioned printer, or send us your old printer for repair. All available from Engineering
Systems.
From C50’s No. C50-120-9747 the printer can be removed by unscrewing 2 screws in the outer casing.
On C50’s C50-119-9737 and older, the outer casing must be removed before the printer can be accessed.
The later machines are fitted with faster printers.
Printer rolls become difficult to feed into the mechanism:
Try cleaning the drive roller in the printer. If this doesn't help the drive roller is worn and a new printer mechanism (or a new printer) is needed.
Replacing the Printer:
Unfortunately the printer originally fitted to the C50 is now obsolete, however a
replacement printer is available. Contact Engineering Systems for details and pricing of the new printer,
including necessary modifications and installation instructions. Alternatively the machine may be returned to Engineering
Systems to have the new printer fitted.
The date and time are printed incorrectly and cannot be reset:
There is a battery backup, incorporated
into one of the electronic components, and the battery has a minimum life of ten years.
Cure: Fit a new battery back up RAM. See
below for fitting instructions. The part number is DS1244Y-70+ and can be obtained directly from Maxim, from RS Components (part no 786-0736) or from Engineering Systems.
The Statistics are continuously printed out once the STATS button has been pressed:
This may be caused by a
faulty clock RAM. Replace the RAM as described below.
Replacing the Clock / RAM Chip:
Unplug the machine from the mains and place it upside down on a bench taking care not
to damage the perspex guard. Remove the 4 screws in the feet and lift off the bottom cover. Locate the clock chip, component U4,
on the main board, next to the EPROM and remove it, using a small screwdriver to gently lever it out of the socket. Plug the
new clock chip into the socket in the same orientation as the old one, checking the dot on the corner of the chip is at the
same end as the indent in the end of the socket.
Connect the machine to mains power and reset the clock as described in the handbook. Finally refit the bottom cover, stand the machine upright and carry out a NEW SIZE procedure to reset the tablet size. Check all fuctions of the machine work as expected. Note that the tablet count will be reset to zero and any stored results will be lost. Also the mean-of-means setting may need changing.
Motor drive faults:
Usually this is a fault with the power amplifier that drives the motor rather than the
motor itself.
Cure: Fit a new power amplifier and 2 other associated electronic components. These components all plug into sockets and are
directly accessible when the bottom cover has been removed (4 screws). This repair is relatively simple and does not involve any
tools other than a screwdriver. We can supply the spare parts.
Various minor modifications have been made to the electronics over the years, and a number of different hardware revisions exist. Some older machines have been updated to the latest hardware revision. If you need to contact us, please quote the serial number (found inside the waste drawer compartment) so that we can check which hardware is fitted.
Repair status for the CT5
As of 2014, we intend to continue to repair these wherever possible. However, a number of parts are starting to become difficult to obtain or obsolete, so we cannot guarantee that all faults can be repaired.
Most of the troubleshooting information for the C50 (above) also applies to the CT5. Some other repairs & modifications specific to the CT5 are:-
Poor speed control:
CT5’s Nos. CT5-030-9715 to CT5-064-0212 inclusive, were fitted with a
motor/tacho system connected by a toothed belt. After a period of time this belt needs to be replaced
otherwise it may break. This will not stop the machine from working but the test speed will not be correct. The belt can
be replaced by removing the top cover of the machine.
Speed display not working:
Press the 'SET SPEED' button and check if the current set speed is displayed. If this is displayed correctly, but the display
stays at 0.00 when the motor runs the tacho belt is probably broken - see above. If the display is blank or missing segments
there will be a fault with the circuitry on the display board. Either repair the fault if competent or return to Engineering
Systems for repair.
Pillar guards:
The latest machines are fitted with telescopic pillar guards to protect the
vertical sliding pillars and to retain the pillar lubrication. Older machines did not have these guards and, depending on usage,
the pillars could become tight, due to lack of lubrication, and in extreme cases seize up in the bronze bearings. This could cause
the motor amplifier to blow and the machine to become inoperable. On these older machines it is necessary to grease the pillars
regularly. The new pillar guards can be fitted to the older machines, but the machines have to be returned to Engineering Systems for retrofit.
Guards:
The later machines are fitted with framed main guards and have magnetic sensor operation. The older guards were prone to
damage if misused and the electrical connection to the rear of the machine was prone to damage. The machines could still
function but the guard switch was inoperative. New style guards can be retrofitted to the older machines but the
machines have to be returned to Engineering Systems.
Repair status for the CT40 and the C40
Whilst we will always try to repair these, given their age (even the newest machine is over 20 years old now) we can't
guarantee that a repair will be possible, as many of the parts are now obsolete.
Some minor faults can be easily repaired: -
Replacing the C40 TEST switch:
If the test cycle fails to start when the TEST button is pressed or it operates the first time after
the machine is switched on but not on further presses, the TEST switch may need replacing. If the TEST LAMP fails to work the
switch may also need replacing, but check the lamp first.
A new switch assembly can be obtained from RS Components. The part numbers are as follows:
Switch: 335-659
Lens: 335-788
Lamp: 655-9665
Parts from the old switch are not compatible with the new one so a complete new set of parts will be required. The switch can be changed by removing the bottom cover, disconnecting the switch wires and removing the old switch. Assemble the new switch and fit it into the cut-out. The arrangement of the wiring is different to the old switch and should be connected as follows:
C40 Test Switch
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1: Yellow / Black
2: Green / Yellow
3: Orange / Black
4 - 6: No Connection
7: Green / Red
8: Pink
Connections are shown viewed from the rear of the switch.
C40 Paper Feed Switch:
The paper feed switch is part of the printer assembly. A replacement switch is
available from RS Components, part number
336-731. Remove the printer from the C40 and prise the button from the front of the
switch to reveal a nut underneath. Remove this nut to free the switch. After
soldering the 2 wires to the new switch the printer can be re-assembled by reversing
the above procedure.
Repair and maintenance of other Engineering Systems products
Please contact us about repairs or maintenance of any other Engineering Systems prodcuts, such as the CK10 and ET500. Please note that we don't undertake servicing or calibration of testing machines from other manufacturers.