NCAT 1087 MANUAL.pdf

1LT1087X2 8/23/00

BARNSTEAD|THERMOLYNE CORPORATION

Model No. Phase Voltage Watts Amps

F85930 1 220-240 4879/6379 20/27

F585938 1 208 5757 28

F85930-33 1 220-240 4879/6379 20/27

45-3790/01 1 220-240 4879/6379 20/27

45-3790/07 1 208 5757 28

NCAT Asphalt Content TesterOPERATION MANUAL

AND PARTS LISTSeries 1087

Rev. G Software

2Table of Contents

Safety Information .............................................................................................................................................. 4Alert Signals ....................................................................................................................................................... 4Warnings ............................................................................................................................................................ 4Introduction ........................................................................................................................................................ 6Intended Use ...................................................................................................................................................... 6General Usage ................................................................................................................................................... 6Software Updates............................................................................................................................................... 6Theory of Operation ........................................................................................................................................... 7General Specifications ....................................................................................................................................... 8Environmental Conditions .................................................................................................................................. 9Declaration of Conformity .................................................................................................................................. 9Unpacking ........................................................................................................................................................ 10Contents of Carton ........................................................................................................................................... 11Installation ........................................................................................................................................................ 12Site Selection ................................................................................................................................................... 12Electrical Connections ...................................................................................................................................... 13Exhaust Installation Tips .................................................................................................................................. 14Balance Installation .......................................................................................................................................... 15Balance Assembly ............................................................................................................................................ 15Setra Balance Operating Instructions When Used in Type F85900 NCAT Furnaces ...................................... 18Balance Control Ports ...................................................................................................................................... 18The Balance Default Settings When Used in the Type F85900 NCAT Furnace .............................................. 18To Set the Time and Date Settings ................................................................................................................... 18To Set the Time ................................................................................................................................................ 19To set the Date ................................................................................................................................................. 19To Span Calibrate the Balance ........................................................................................................................ 20To Set Factory Defaults .................................................................................................................................... 21To Escape Configuration Menu ........................................................................................................................ 22Lift Test Procedures ......................................................................................................................................... 22Printer Operation .............................................................................................................................................. 23Printer Access .................................................................................................................................................. 24Paper Advance Button ..................................................................................................................................... 24Paper Tape Rolls .............................................................................................................................................. 24Conserving Paper ............................................................................................................................................ 24Paper Tape Roll Installation ............................................................................................................................. 25Printer Record Storage .................................................................................................................................... 26Operation ......................................................................................................................................................... 27Displays ........................................................................................................................................................... 27Controls ............................................................................................................................................................ 27To Change the Setpoint Temperature .............................................................................................................. 28To Change The Initial Sample Weight .............................................................................................................. 28To Change the Calibration Factor .................................................................................................................... 28To Tare the Balance ......................................................................................................................................... 29Outline of Operational Procedures ................................................................................................................... 29Timer Mode ...................................................................................................................................................... 31Programmable Timer ....................................................................................................................................... 31Programming the Timer .................................................................................................................................... 31

3Inactivity Mode ................................................................................................................................................. 31Interrupting the Timer Mode ............................................................................................................................. 32Methodology and Test Tips .............................................................................................................................. 33Software Features ............................................................................................................................................ 35Equations Used to Determine Bitumen Ratio ................................................................................................... 35Test Interrupt/Power Interrupt ........................................................................................................................... 35Auto Shutdown Mode ....................................................................................................................................... 36Positive Calibration Factor ............................................................................................................................... 36Stability Threshold ............................................................................................................................................ 36Serial Port Output/Operation ............................................................................................................................ 37Sample Data Output ......................................................................................................................................... 37Description of Sample Data ............................................................................................................................. 38Explanation of Error Codes .............................................................................................................................. 39Furnace Error Codes ........................................................................................................................................ 39Setra Balance Error Codes .............................................................................................................................. 40Hidden Key Routines ....................................................................................................................................... 41Preventative Maintenance and Servicing ......................................................................................................... 49Element Plate Construction Use & Care .......................................................................................................... 49To Replace a Chamber Heating Element ......................................................................................................... 50To Replace a Filter Heating Element ................................................................................................................ 51To Replace a Type K Chamber Thermocouple ................................................................................................ 52To Replace a Solid State Relay ........................................................................................................................ 53To Replace a Fuse ........................................................................................................................................... 55To Realign Door Switch (Microswitch) .............................................................................................................. 56To Realign Door Lock ....................................................................................................................................... 56Replacement Parts ........................................................................................................................................... 57Exploded View (Insulation and Filter) ............................................................................................................... 59Exploded View (Elements) ............................................................................................................................... 60Ordering Procedures ........................................................................................................................................ 61Decontamination Statement ............................................................................................................................. 61Wiring Diagram ................................................................................................................................................ 62Wiring Diagram Component List ...................................................................................................................... 63Amperage Configurations ................................................................................................................................ 64Glossary ........................................................................................................................................................... 65One Year Limited Warranty .............................................................................................................................. 68

4WarningBarnstead/Thermolyne does notcondone the use of this product for thepurpose of cleaning glassware, such asrolling thin film oven bottles. Prior toignition, the asphalt in these bottles willliquify and may flow into the lowercontrol section of this product, causingsevere damage or fire.

Alert Signals

WarningWarnings alert you to a possibility ofpersonal injury.

CautionCautions alert you to a possibility ofdamage to the equipment.

NoteNotes alert you to pertinent facts andconditions.

Hot SurfaceHot surfaces alert you to a possibilityof personal injury if you come incontact with a surface during use orfor a period of time after use.

This manual contains important operating and safetyinformation. You must carefully read and understand thecontents of this manual prior to using this equipment.Your NCAT Asphalt Content Tester has been designed withfunction, reliability and safety in mind. It is your responsibilityto install it in conformance with local electrical codes. For safeoperation, please pay attention to the alert signals throughoutthe manual.

WarningsTo avoid electrical shock:

1. This furnace must be installed by a competent,qualified electrician who ensures compatibilityamong furnace specifications, power source andservicing.

2. Disconnect from power supply before servicing.

3. Ensure that the furnace is not connected to thepower supply prior to installing or removing thebalance.

4. Ensure that the door switch is operating properly.

To avoid burns:1. Do not touch the exterior or interior surfaces of the

chamber or exhaust area when chamber is hot.Hot Surface. Avoid Contact with Chamber Area.

To avoid personal injury:1. Do not use in the presence of flammable or

combustible materials, including cutback asphalts;fire or explosion may result. This device containscomponents which may ignite such material.

2. Refer servicing to qualified personnel.

3. Allow the furnace to cool to room temperaturebefore performing any maintenance or servicing.

4. Failure to connect the exhaust port to anappropriate exhaust system will result in smokeand gases entering the work area. Without theconnection, gases and smoke will escape from thefurnace.

5WarningRefer servicing to qualified personnel.

5. This furnace contains refractory ceramicinsulation which can produce respirable fibersand dust when handled. These fibers can causeirritation and can aggravate preexistingrespiratory disease. The International Agency forResearch on Cancer (IARC) has classifiedrefractory ceramic fiber as possibly carcinogenic.After service refractory ceramic fiber dust maycontain crystalline silica, which may cause lungdamage (silicosis) and which has been classifiedby IARC as a carcinogen.

WarningThis warning is presented for compliance with CaliforniaProposition 65 and other regulatory agencies and onlyapplies to the insulation in this product. This productcontains refractory ceramic, refractory ceramic fiber orfiberglass insulation, which can produce respirable dust orfibers during disassembly. Dust or fibers can cause irritationand can aggravate preexisting respiratory diseases.Refractory ceramic and refractory ceramic fibers (afterreaching 1000C) contain crystalline silica, which can causelung damage (silicosis). The International Agency forResearch on Cancer (IARC) has classified refractoryceramic fiber and fiberglass as possibly carcinogenic(Group 2B), and crystalline silica as carcinogenic to humans(Group 1).

The insulating materials can be located in the door, thehearth collar, in the chamber of the product or under the hotplate top. Tests performed by the manufacturer indicate thatthere is no risk of exposure to dust or respirable fibersresulting from operation of this product under normalconditions. However, there may be a risk of exposure torespirable dust or fibers when repairing or maintaining theinsulating materials, or when otherwise disturbing them in amanner which causes release of dust or fibers. By usingproper handling procedures and protective equipment youcan work safely with these insulating materials andminimize any exposure. Refer to the appropriate MaterialSafety Data Sheets (MSDS) for information regardingproper handling and recommended protective equipment.For additional MSDS copies, or additional informationconcerning the handling of refractory ceramic products,please contact the Customer Service Department atBarnstead|Thermolyne Corporation at 1-800-553-0039.

SAFETY INFORMATION

6Congratulations on your purchase of aBarnstead|Thermolyne NCAT Asphalt Content Tester.

IntroductionThe unit is designed to perform a specific test within yourlaboratory. Please read the instructions carefully to ensurethat you receive maximum benefit from it. Also, be sure tofill out and return the enclosed warranty registration card.We would like to receive the information requested, and itwill help us assure you of proper warranty coverage.

Intended UseThe NCAT Asphalt Content Tester is an analyzer whichdetermines the asphalt content of a sample by loss onignition per standard methods. The asphalt sample isbathed in oxygenated air and weighed continuouslythroughout the ignition procedure. The NCAT AsphaltContent Testers software identifies the endpoint of ignitionand indicates the completion of the test. Results aredocumented by a printer.

General UsageDo not use this product for anything other than its intendedusage.

Software UpdatesSoftware improvements are initiated based on marketfeedback. Currently your tester contains Revision Gsoftware. You will be notified by your sales representative,distributor or Barnstead|Thermolyne as a softwareimprovement becomes available. A software packetincludes installation instructions, operational data and anEPROM. The EPROM is easy to install and can be installedwithin a few minutes.

Introduction

7Theory of OperationThe furnace is heated to a setpoint temperature withinthe range of 450 - 550C.

The hot mix asphalt sample is weighed, equally dividedand placed in two screened baskets which are mountedon a tray assembly. This complete assembly is placed onthe furnace hearth tray. The hearth tray is mounted onfour ceramic support tubes, which are in turn mounted ona digital balance platform. A blower draws ambient airthrough the four ceramic tube support openings locatedon the chamber floor. This oxygenated air saturates thespread asphalt sample to promote ignition and ashing.The released volatiles are further oxidized while passingthrough a ceramic filter heated to 750C in a chamberabove the main chamber. Five air exit ports direct theexhausted air to a louvered plenum. The exhaust is thencooled by mixing with ambient air. The blower thendirects the exhaust through the plenum exhaust port.Standard seamless exhaust tubing directs the exhaust toan outside exhaust system.

INTRODUCTION

8Model F85930-33, F85940-33, 45-3790/07, F85948,45-3790/01, F85930 (240 V) F85938 (208V)

Overall Dimensions Width 21.375 (54.29) 21.375 (54.29)IN. (CM) Height 40.500 (102.87) 40.500 (102.87)

Depth 25.625 (65.09) 25.625 (65.09)Chamber Dimensions Width 14.000 (35.56) 14.000 (35.56) IN. (CM) Height 14.000 (35.56) 14.000 (35.56)

Depth 14.000 (35.56) 14.000 (35.56)Weight Lbs. (KG) 302 (137) 302 (137)Electrical Ratings Volts 220-240 208

Amps 20/27 28Watts 4879/6379 5757Freq. 50/60 50/60Phase 1 1

Chamber Temperature Ratings* 100C-650C 100C-650CMax. Sample Cap. 5 kilograms of

asphalt sample.Max. Operating Chamber 650C 650CTemp. Filter 900C 900CMaximum ProgramRun Time 255 minutes 255 minutesAllowable Values for Chamber Set point 100C-650C 100C-650CSelected Functions Filter Set point 0C-900C 0C-900C

Sample Weight 100g-5000g 100g-5000gCorrection Factor 0.00-99.99 0.00-99.99Wake up Time 0:00-24:00 0:00-24.00Wake up Date 0.00 - 12.31 0.00 - 12.31Inactivity Check On/Off On/OffAuto Shut down On/Off On/OffBeeper On/Off On/OffSerial Port Output Continuous/Test Only Continuous/Test OnlyChamber Calibration Offset +50 to -50 +50 to -50Test Stability Threshold 0.01-0.5% 0.01-0.5%Intermediate Printing (Internal Printer) On/Off On/Off

Default Values for Chamber Set point 538C 538CSelected Functions Filter Set point 750C 750C

Sample Weight 1200g 1200gCorrection Factor 0.00 0.00Wake up Time 5:00 5:00Wake up Date 0.00 0.00Inactivity Check On OnAuto Shut down On OnBeeper On OnSerial Port Output Continuous ContinuousChamber Calibration

General Specifications

9 Offset 0C 0CTest Stability Threshold 0.01% 0.01%Intermediate Printing (Internal Printer) On On

* Maximum temperature can be achieved at the maximum line voltage specified on the Specification Plate.

Environmental ConditionsOperating: 17C - 27C; 20% - 80% relative humidity, non-condensing. Installation Category II (overvoltage) inaccordance with IEC 664. Pollution Degree 2 in accordance with IEC 664.Altitude limit: 2,000 meters.Storage: -25C - 65C; 10% - 85% relative humidity.

Declaration of Conformity(-33 models only)Barnstead/Thermolyne hereby declares under its sole responsibility that the model 45-3790/01 (F85940-33)conforms with the technical requirements of the following standards:

EMC: EN 50081-1 Generic Emission StandardEN 50082-1 Generic Immunity StandardEN 61326 Electrical equipment for measurement, control and laboratory use -

EMC requirements - Part I: General Requirements.Safety: EN 61010-1-92 Safety requirements for electrical equipment for measurement, control

and laboratory use; Part I: General RequirementsEN 61010-2-010 Part II: Particular requirements for laboratory equipment for

the heating of materials

per the provisions of the Electromagnetic Compatibility Directive 89/336/EEC, as amended by 93/68/EEC, andper the provisions of the Low Voltage Directive 73/23/EEC, as amended by 93/68/EEC.

The authorized representative located within the European Community is:Electrothermal Engineering, Inc.419 Sutton RoadSouthend On SeaEssex SS2 5PHUnited Kingdom

Copies of the Declaration of Conformity are available upon request.

GENERAL SPECIFICATIONS

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Unpacking1. Visually check for any physical damage to the

shipping container. Remove the furnace from theshipping container. Inspect the equipmentsurfaces that are adjacent to any damaged areaof the shipping container. Retain damagedpacking material. File claim with the deliverycarrier if damage is incurred.

2. Open the furnace door and carefully removepacking material from inside the furnacechamber. Remove the screws (4) securing thefront display panel. Open the front display panel.Vacuum the chamber and the balance supportplate (beneath the chamber) prior to use toremove the insulation dust which may haveaccumulated during shipment. Wear a dust maskand gloves while cleaning.

3. Remove the balance, ceramic posts, fuses,manual and hearth tray from the shippingcontainer.

4. Retain the original packaging material ifreshipment is foreseen or required for mobile labuse.

Allow adequate work area and bench space for loading andunloading. Locate the cooling plate alongside the furnace toallow for convenient transport of hot loads.

Unpacking

NoteThe NCAT Asphalt Content Testerdoes not come with a power cord. Thefurnace has the capability of beinghard wired or having a power cordattached depending on your localelectrical code requirements.

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Each palletized furnace carton contains:1 Asphalt Content Tester

1 Electronic Balance

1 Hearth tray, gray silicon carbide

8 Ceramic tube supports, Inside Furnace Chamber

1 Instruction Manual, Inside Furnace Chamber

6 Replacement Fuses

Accessory Kit ContentsPart # AY1087X1Two basket assemblies consisting of:

2 Basket Retainer Brackets

2 Transport and Catch Trays

2 Top Baskets

2 Bottom Baskets

2 Covers for Top Baskets

1 Transport Handle

1 Aluminum Cooldown Plate

1 Cooldown Safety Cage with HOT Sign

1 Face Shield with Head gear

1 Pair High Temperature Gloves

1 Can of Fan Motor Lubricant

1 Stainless Steel Basket Brush

4 Rolls of Thermal Printer Paper

Optional purchase:

1 Length of exhaust tubing (3" I.D. x 10', shippedin a separate carton), part # TU859X1

Contents of Carton

12

Site SelectionPlace the furnace on a sturdy level surface about 26-28inches high and capable of supporting the weight of the fullyassembled furnace. Furnace must be placed on a levelsurface to permit door to safely swing and remain open forloading and unloading. Allow space for air flow around thefurnace (6" minimum). Locate the furnace so you can directthe furnaces emissions through ducting to a fume hood orother appropriate ventilation system. We recommend anexhaust length of not more than 10 feet, if possible.Leveling feet are adjustable. The furnace should be leveledso the door will remain open.

Installation

CautionBe sure ambient temperature does notexceed 40C (104F). Ambients abovethis level may result in damage to ormalfunction of the controller.

Allow at least 6 inches of spacebetween the furnace and any verticalsurface. This permits the heat fromfurnace case to escape so as not tocreate a possible fire hazard.

Hot SurfaceDo not install above or nearflammables.

13

INSTALLATION

Figure 2 Terminal Block Connections

WarningTo avoid electrical shock, this furnacemust be installed by a competent,qualified electrician who ensurescompatibility among furnacespecifications, power source andground code requirements.

CautionFor supply connections, use 10 AWGor larger wires suitable for at least90C. Failure to observe this cautioncould result in damage to furnace and/or work area.

NoteDo not operate the 220-240 volt NCATAsphalt Content Tester on 208 volts.Your test results will be negativelyaffected by the lower voltage. Consultwith your supplier if this is the case.

Electrical ConnectionsThe electrical specifications are:Volts Amps Watts Hertz220-240 20/27 4879/6379 50/60208 28 5757 50/60

Your furnace is factory configured for a 27 amp supply. Youhave the option of re-configuring the wiring at the back ofthe furnace for 20 amps. Please see page 64. Typically, a20 amp configuration is used for mobile laboratoryinstallations or if your supply is only rated for 20 amps.

Prior to connecting your asphalt testing furnace to yourelectrical supply, be sure the front power switch and rearcircuit breaker are in the OFF position.The power supply entry is located at the right rear of thelower case (as you face the rear of the unit). A terminalblock is located behind an access plate. Remove the sixscrews retaining the plate covering the terminal connectionblock. The line and ground connections to the terminalblock are depicted in Figure 2.

Your NCAT Asphalt Content Tester may be wired eitherdirectly through a conduit system or by using a power cordand plug. Electrical wiring should conform to your localelectrical code requirements.

14

INSTALLATION

Exhaust Installation Tips1. Select a location to minimize exhaust length.

We recommend an exhaust length of not morethan 10 feet.

2. Flexible 3 I.D. seamless steel tubing orelectrogalvanized steel tubing isrecommended for venting. Lightly sealconnections at blower exit at the top of thetester with clear silicon such as DOW >32 orGE RTV or equivalent. Use sparingly so theexhaust tube can be detached for servicing.Do not use galvanized tin dryer pipe ordouble-wall galvanized tin as the seams willleak fumes into the lab. Do not use vent pipethat is reduced to less than 3 I.D.

3. Minimize 90 bends in your exhaust system ifpossible. Bends restrict the exhaust air flowand tend to accumulate particulates which canalso restrict air flow.

4. Termination of your exhaust system may be inopen air or to a larger exhaust duct. Open airtermination is the most efficient. Ducttermination should not be in the vicinity offresh air intakes. Also, the duct cap must notrestrict the air flow.

Exhausting into a larger duct requires anairtight connection. The larger duct must notcreate a positive air pressure internally whichcan diminish the testers blower efficiency.Perform the lift test to ensure a -3.2 to -8.2gram lift. (See page 22). Increasing thevelocity of the exhaust flow above the lift of

NoteAppropriate exhaust must be providedto remove smoke and gases producedin a testing procedure. Seamlessflexible exhaust tubing with an insidediameter of 3 is recommended.Seamless flexible 3 steel tubing isavailable. (See Replacement Partslist.)

The exhaust exiting the furnaceexhaust port may reach 270C. Do notuse flammable materials or materialswith a low melting point for exhausttubing.

WarningFailure to connect the exhaust port toan appropriate exhaust system willresult in smoke and gases entering thework area. Without the connection,gases and smoke will escape from thefurnace.

CautionDo not connect the exhaust port totubing less than 3 in diameter orotherwise restrict the exhaust flow fromthe furnace. Also, do not connect thetubing directly to an external fan orotherwise increase the velocity of theexhaust flow from the furnace. Eitherrestricting or increasing the exhaustflow from the furnace may damage thefurnace or reduce its efficiency.

15

-8.2 grams may blow fines from the basketresulting in an exaggerated asphalt cementcontent.

5. Turn on fume hood blowers and conduct lift testto ensure the -3.5 to -10 gram lift is maintained.Perform the test with room doors open andclosed to ensure proper makeup air for the room.

Balance InstallationThe NCAT Asphalt Content Tester is supplied with anelectronic balance, for use in the NCAT Asphalt ContentTester. The balance operates on voltage supplied by thetester.

The balance is shipped in a separate carton containingspecialized packaging material. It is recommended that thespecialized carton and packaging be retained for safebalance storage or reshipment.

The balance carton will contain the following:1 Balance1 Support plate1 Catch pan4 Screws

Balance AssemblyInstall support plate onto balance load cell with the screwsprovided as shown.

To install the balance:

1. Ensure that the furnace is disconnected from thepower supply. Remove the four screws along thetop of the front control panel securing the controlpanel to the lower case of the furnace. Movefurnace forward about 2 inches beyond counter

INSTALLATION

Balance Assembly

NoteThe balance is shipped separately toensure that the balance is notdamaged during shipment.

16

edge or adjust all feet up about 1/4 inch. Thiswill allow the hinged control panel to openwithout obstruction.

2. Open the lower case by carefully pulling thecontrol panel forward and downward. Thecontrol panel is hinged on the bottom edge tothe lower furnace case. Do not allow the panelto fall completely open as this mayexcessively strain cables attached to thepanel.

3. Inside the lower furnace case, observe thesuspended table (balance support plate)supported by four aluminum rods. Thebalance will be supported by this table.Vacuum the table if dust, etc., appears on it.

4. Mount the support plate and the catch pan onthe balance. Note the four pins on thecatchpan. These will retain the ceramicsupport tubes, which will project into thefurnace chamber after mounting.

5. Place the Setra balance on the balancesupport table so that the gray ribbon cable isprotruding from your left. This gray ribboncable will be plugged into the front paneldisplay board, into the connector marked P2.On this same display board, the connectormarked P6 should have a red and whitepower jack cable plugged into it, and theconnector marked P3 should have a 9-pinribbon cable connected to it. All three of theseconnections are necessary in order for theSetra balance to function.

6. Position the balance so that the pins on theplatform support plate are directly beneath thefour tube ports in the bottom of the furnacechamber.

INSTALLATION

WarningEnsure that the furnace is notconnected to the power supply prior toinstalling or removing the balance.

NoteDo not close the control panel yet.

17

7. Open the furnace door. Insert the four ceramicsupport tubes through the tube ports located inthe bottom of the furnace chamber. Adjust theposition of the balance until the four ceramicsupport tubes are seated on the appropriate pinson the balance plate. Finely adjust the position ofthe balance until the tubes are centered in theirports, but not touching the sides of the ports.

8. Place the 10 x 11 gray silicon carbide hearthtray on the four ceramic support tubes with the11 dimension from front to back. Position thefront of the hearth tray about one inch back fromthe lip of the bottom element plate. Center thehearth tray on the four support tubes, equallydistant from side to side.

9. Close the lower case by returning the controlpanel to its original position. Secure the controlpanel with the four screws you removed in step1.

10. Switch the main circuit breaker (located on thelower left rear corner of the case when facing thefront of the furnace) on. Close the furnace doorand switch the power switch on. The balancedisplay board will read 0.0 grams afterapproximately 20 seconds of initialization. Turnpower off and reposition the balance if thedisplay is unstable or reads anything other than0.0 grams. Instability may be caused by one ofthe support tubes rubbing.

INSTALLATION

CautionDo not allow the ceramic support tubesto contact the sides of the tube ports,as this will cause an unstable andinaccurate balance readout.

18

Setra Balance OperatingInstructions When Used In TheType F85900 NCAT Furnaces

Balance Control Ports:

ENTER Not used Not used ON/OFF

The Balance Default Settings When Usedin the Type F85900 NCAT Furnace:

Time: 24 hour format (0 to 24 hours).Date: US type, 2 Digit Year format, Use the 2-digit yearonly.

Examples: 23:30:3012/29/97

To Set the Time and Date Setting

The balance supplies the date and time to the furnacecontroller. For ease of record keeping, you should set thetime to reflect your local time and date.

We recommend preforming a hidden weight key routine toprint the initial date and time before making any changes.After changing the date and time, print the information againand compare to be certain you changed it correctly.

INSTALLATION

NoteThe balance control buttons can beaccessed through the pin holeslocated on the right front furnacecontrol panel, below the balanceindicator, with a tool of .063 diameteror smaller.

19

To Set the Time

1. Switch the green power switch down to OFF.

2. While holding the 4 key down, switch thegreen power switch up to ON, the red displayshould indicate [BAL CAL].

3. Press and hold the balance ON/OFF key.

4. Press the balance ENTER key, then releaseboth keys. 71nE will be displayed, press thebalance ENTER key. The two hour digits willbe blinking (Note the time is in a 24 hour format).

5. Press the balance ON/OFF key until thecorrect hour is displayed.

6. Press the balance ENTER key, the two minutedigits will be blinking.

7. Press the balance ON/OFF key until thecorrect minute is displayed.

8. Press the balance ENTER key, the balance willreturn to the normal weight display.

To Set the Date




4. Press the balance ENTER key, then releaseboth keys. [71nE] will be displayed, press thebalance ON/OFF key, [dA7E] will be displayed.

INSTALLATION

20

5. Press the balance ENTER key, [US] (UnitedStates) or [Eur0] (European) date type will bedisplayed.

6. Press the balance ON/OFF key until thedesired type is displayed.

7. Press the balance ENTER key, [2d Yr](Two digit year) or [4d Yr] (Four digit year) willbe displayed.

8. Press the balance ON/OFF key until thedesired format is displayed.

9. Press the balance ENTER key, [dAY XX] (Day)will be displayed.

10. Press the balance ON/OFF key until thedesired day is displayed.

11. Press the balance ENTER key , [nn0 XX](Month) will be displayed.

12. Press the balance ON/OFF key until thedesired month is displayed.

13 Press the balance ENTER key, [Yr XX] (Year)will be displayed.

14. Press the balance ON/OFF key until thedesired year is displayed.


To Span Calibrate the Balance


2. After furnace has cooled to roomtemperature, open the furnace door.

3. Remove and clean any debris from the ceramicload plate, balance load plate, and ceramicsupport posts, replace posts and plates.

INSTALLATION

21



6. Press the balance ENTER key, then releaseboth keys. [71nE] will be displayed, press thebalance ON/OFF key twice, [CAL] will bedisplayed.

7. Press the balance ENTER key, [LOAd 8000]will be blinking on the display.

8. Place an 8000 gram (NIST traceable) weighton the ceramic load plate in the furnace.

9. Press the balance ENTER key, the balancewill display [ACAL], then return to the normalweight display.

To Set Factory Defaults




4. Press the balance ENTER key, then releaseboth keys. [71nE] will be displayed, press thebalance ON/OFF key three times, [FACdEF]will be displayed.

5. Press the balance ENTER key, the balancewill display [BUSY], then return to the normalweight display.

INSTALLATION

NoteThis function is to reset parametersinside the balance which are not useraccessible, the TIME, DATE, andBALANCE CALIBRATION areunaffected.

NoteThe balance must display 0.0 beforedoing calibration.

NoteFurnace door should remain openduring the balance calibration.

22

To Escape Configuration Menu

1. Press the balance ON/OFF key until [ESCAPE]is displayed.


Lift Test ProceduresThe efficiency of the blower and/or exhaust system isindirectly monitored by a quick test procedure named thelift test. The procedure is detailed as follows:

1. Fully assemble tester with exhaust systemattached, hearth tray is mounted on the fourceramic support tubes, and at room temperaturewith no load. This test should always beperformed with the furnace chamber at roomtemperature.

2. Depress power switch to the on position.Depress 0 key to tare balance display.

3. Push program start button. Blower will turnon. Observe balance display reading. Displayshould read -3.2 to -8.2 grams. Detach theexhaust system and repeat the test to determineif the exhaust system is restricting the tester airexchange, if the initial test is out of spec or isborderline spec on the -3.5 grams low side.

INSTALLATION

CautionPerform the lift test only when thefurnace is at room temperature.

23

Printer Operation

The printer automatically prints a record of your furnacesoperation. When you press Start/Stop, the printer will printthe current date, then the current time. The printer will thenprint a space for you to record a sample identificationnumber, another space for you to record the mix type, and athird space for you to record the testers name oridentification number. The printer will then print the filtersetpoint and chamber setpoint.

After the printer has printed all this header information, it willprint a column header line T:TEMP:WT.LOSS:%LOSS.The first column is elapsed minutes. The second column isthe main chamber temperature in C. The third column isdirect weight loss in grams, and the fourth column is theuncorrected percentage of sample weight lost. The printerwill print the current values of those four measurementsevery minute during the test.

When you press Start/Stop to complete your test, theprinter will print the calibrated asphalt content, the BitumenRatio, the calibration factor used during the test, thetemperature compensation factor used during the test, thetotal uncorrected percentage of the sample weight lost, thetotal weight lost in grams, the initial sample weight and thetotal elapsed time for the test.

If the printer runs out of paper during the test, the test willnot halt, though the printer will not continue to print. Yourresults will be safely stored and accessible, providing youhave spare rolls of paper. If possible, install a new roll whileyour test is still running. The printer will resume printing atthat point.

If the test is completed before you install a new roll of paper,press Start/Stop to conclude the test. Prn will bedisplayed in the Elapsed Time window. This indicates thatthe printer ran out of paper during a test and a new roll ofpaper was not loaded. Provided that you do not start anothertest, you can still retrieve the results of the test. After youload a new roll of paper, press Enter. The results of the lasttest will print. This feature is always available after you run atest, and you can print multiple copies of the results of a testsimply by pressing Enter repeatedly after your test iscompleted. Allow the printer to finish printing before pressingEnter again for additional printouts.

CautionThe printer uses thermal paper which issensitive to heat and light. Radiatedheat from the hot basket assembly canblacken the test data on the tape. Storetape in a cool, dark environment. Thetest results and header can be printedagain by depressing the Enter key.The results will not be printed if furnaceis powered down or a new test was run.

NoteA colored stripe along the edge of thepaper indicates that you areapproaching the end of the roll. Whenthe stripe appears, approximately 18inches of paper remain. Replace theroll before it is completely exhausted toensure a complete record of your testprocedures.

24

Printer AccessThe printer is protected by a protective cover. The printercover pulls off the front when you squeeze the buttons oneach side and pull forward. The printer will then slideforward when you pull gently on the metal tab provided onthe leading edge of the printed circuit board.The printed paper tape exits the printer through a slot in theprotective cover. The serrated slot provides a clean tearingof the taped test results. Use only printer tape specified byBarnstead|Thermolyne or your Barnstead|Thermolynedistributor.

Paper Advance ButtonA paper advance button is located on the upper right cornerof the printer. Pressing the paper advance button while theprinter is inactive will advance the paper through the printer.The paper advance button is useful for installing a new rollof paper tape and for advancing a tape for tearing off at theend of a test.

Paper Tape RollsThe special heat sensitive paper for the printer is availablefrom Barnstead|Thermolyne or your Barnstead|Thermolynedistributor (Part Number PRX2). The printer will not print onplain paper. For paper roll installation, see next page.

Conserving PaperIf you dont require them, you can turn off the printing ofintermediate values and only print initial values and finalresults. This will save a significant amount of paper per test.To turn off the printing of intermediate values:

Depress power switch to on while simultaneouslydepressing the 1 key. Depress the power switch to off toexit procedure. See Hidden Key Procedures for moredetails.

PRINTER OPERATION

Test Results Printout

25

Paper Tape Roll InstallationThe heat sensitive paper will print on only one side, andtherefore, must be installed properly to function.

1. Switch furnace power on. Press the PaperAdvance button to feed out any paperremaining in the printer.

2. Remove the printer cover and pull out theprinter as described in Printer Access.

3. Cut the lead end of the replacement paper asshown in the illustration. Remove at least sixinches of the lead end of the paper to removethe adhesive which secured the roll forshipping.

4. Insert the paper roll on the paper roll shaft asshown.

5. Feed the cut end of the paper into the slot atthe bottom of the printer (A). Push the feedbutton on the front of the printer until about 1of paper comes out the front of the printer.

6. Feed the paper through the cover and reinstallthe cover.

PRINTER OPERATION

Figure 3Paper Roll Installation

NoteAt the end of each day, the printedportion of the printer tape should beremoved and stored in an appropriateway. See Printer Record Storage fordetails.

26

PRINTER OPERATION

Printer Record StorageIn addition to being heat-sensitive, the paper tape is alsolight sensitive and will darken if left exposed to light for anextended length of time. To ensure the long-term legibilityof your records, choose one of the following methods:

1. Photocopy each days tapes and file thephotocopy.

2. Store the tapes in an opaque folder, file orenvelope.

Note that certain situations and substances will hasten thedegradation of the thermal paper and should be avoided:

1. Exposure to heat or hot surfaces will darken thepaper and obliterate your readings.

2. Ultraviolet light will darken the paper andobliterate your readings. Common fluorescentlights emit low levels of ultraviolet light; thermalpaper tapes left exposed to fluorescent light in alab or office will eventually darken and becomeunreadable.

3. Common cellophane tape interacts with thethermal paper and will darken it to illegibility. Usecare if you tape your original thermal papertapes into a notebook.

27

DisplaysThe furnace has four displays, labeled Chamber Temp.,Percent Loss, Elapsed Time and Balance Indicator.

Chamber Temp. displays the current temperature of themain chamber in C. If you press the Temp. button on thekeypad, the Chamber Temp. display indicates the currentsetpoint for the furnace chamber. The Setpoint LED willilluminate when the setpoint is displayed.

Percent Loss displays the percentage of the total sampleweight currently consumed by combustion. When you pressthe Weight button on the keypad, Percent Loss displaysthe last sample weight you entered. When you press theCalib. Factor button on the keypad, Percent Lossdisplays the last calibration factor you entered.

Elapsed Time displays the elapsed time since you startedthe test. Pressing the Start/Stop button starts a test.Pressing the Start/Stop button stops a test and also stopsthe timer and freezes the Elapsed Time display until thenext test is started.

Balance Indicator displays the weight change of thesample, in grams (only during a test).

Balance Stability Indicator is a flashing LED locatedwithin the balance indicator window. The indicator normallyflashes throughout the test period as the sample losesmass during the ignition process. The indicator willtypically remain full on when the mass becomes stable.

ControlsTo View the Current Settings of the Controller:Press the Temp. button to view the current chambersetpoint on the Chamber Temp. display. Press theWeight button to view the initial weight of the last sampleon the Percent Loss display. Press the Calib. Factorbutton to view the current calibration factor on the PercentLoss display.

Operation

NoteOther parameters can be adjustedthrough the Hidden Key Routines,explained on page 41 of this manual.

NoteIf you do not press any other keys, thedisplays will revert to their standarddisplays after five seconds.

28

To Change the Setpoint Temperature:1. Press the Temp. button. The Chamber Temp.

display will show the furnaces current setpoint.

2. Enter your new setpoint. Press the Enter buttonto accept your new setpoint. This must be donebefore the Chamber Setpoint light goes out.

3. Press the Temp. button again to verify your newsetpoint.

To Change the Initial Sample Weight:1. Press the Weight button. The Percent Loss

display will show the current initial sampleweight.

2. Enter your new initial sample weight (in grams).Your initial sample weight should be a four digitnumber, in whole grams. Press the Enter buttonto accept your new initial sample weight. Thismust be done before the Sample Weight lightgoes out.

3. Press the Weight button again to verify yoursample weight.

To Change the Calibration Factor:1. Press the Calib. Factor key once to enter a

negative weight loss value and twice to enter apositive value. The Percent Loss display willshow the current calibration value. For acalibration factor of 0.21%, enter 21.

OPERATION

29

2. Enter your new calibration factor. Press theEnter key to accept your new calibration factor.This must be done before the calibration factorlight goes out.

3. Press the Calib. Factor button again to verifyyour new calibration factor.

To Tare Balance:1. Press the 0 key.

Outline of OperationalProcedures

1. Weigh your sample on an external balanceaccurate 1 gram.

2. Enter sample weight into controller. Using theinstructions under To Change the Initial SampleWeight, enter the initial weight of your sample.

3. Check and, if necessary, adjust your temperaturesetpoint and correction factor. See theinstructions under Controls on pages 27-29.

4. Load the basket assembly into the furnacechamber by inserting it directly above the hearthtray and setting gently on the hearth tray. Thecarrier tines of the transport handle will extendpast the rear of the transport tray when locked inplace. As you insert the load into the furnacechamber, allow the carrier tines of the transporthandle to touch the rear wall of the of the furnacechamber, then gently set the load on the hearthtray. This will ensure proper placement of theload from front to back. Check the load for properclearance on each side.

Keep objects away from the thermocouple. Donot slide basket assembly against thethermocouple. This will affect temperaturereading and weight indication.

OPERATION

NoteOnce the test is started, the setpointscannot be changed.

WarningDo not open door while program is inprocess. Flame and noxious fumesmay be released into the laboratory.Operator will be exposed to the risk ofburns. Always allow test program toreach endpoint before opening door.

WarningDo not load cutback asphalt samplescontaining naphtha, gasoline, fuel oil orexplosive volatiles. Explosive ignitioncan occur resulting in a fire or a threatof burns to the operator.

30

Use insulated gloves and a fire retardant apronwhen loading and unloading furnace. Alwayswear safety glasses or a safety face shield andhigh temperature gloves when loading orunloading furnace. Long sleeve, fire retardantattire is recommended. Always keep your glovesand glasses clean. Allow clearance for thebasket tray so it will not touch the doorinsulation. See furnace loading tips.

5. Close the door. The furnace will not operate withthe door open.

6. Press the Start/Stop button.

When you press Start/Stop, the automatic lockingmechanism will lock the door. After approximately five tofifteen minutes of heating (depending on sample size andsample volatility), the asphalt will ignite. You will see asudden increase in the actual chamber temperature(Chamber Temp. display). The main chamber temperaturemay remain significantly higher than your setpointtemperature for some time (again, depending on samplesize and volatility). When the main chamber temperaturebegins to decline, you will also see both the Percent Lossand Balance Indicator displays begin to stabilize. After thesample weight has stabilized, an audible alarm and stablelight will illuminate to signal test completion and the printerwill stop. Note: The printer will only stop if the Auto ProgramSwitching Mode is on. The furnace will continue to heat atsetpoint temperature.

7. Press the Start/Stop button. The automaticlocking mechanism will unlock the door. Useappropriate safety apparel and tools whenunloading the hot furnace. Note: The door willautomatically unlock, if the Auto ProgramSwitching Mode is on.

OPERATION

CautionDo not exceed the 5000 gram capacity.Failure to observe this caution couldresult in damage to furnacecomponents and/or balance.HHHHHH will be displayed on thebalance display if the weight limit isexceeded.

If your load touches either side, thefront or the back of the furnacechamber during a test, the test isinvalid. Balance instability will result.This is typically evidenced by a weightgain on the one-minute printed testresult readout.

WarningDo not use in the presence offlammable or combustible chemicals;fire or explosion may result. Thisdevice contains components whichmay ignite such materials.

Hot SurfaceTo avoid burns, this furnace must notbe touched on the exterior or interiorfurnace surfaces of the chamber area(except door handle and front controlpanel) during use or for a period oftime after use. Hot Surface. AvoidContact.

31

Programmable TimerHeating the furnace to operational levels may require twoor more hours of preheating but leaving the furnace onconstantly may not be efficient, consuming both electricityand heating elements. To optimize your working hours, wehave designed an automatic preheat timer into your asphalttesting furnace. This feature allows you to begin workimmediately each day, but only run your furnace as muchas necessary to complete your days work.

Programming the TimerThe following directions will explain how to program thewake up date and time into your asphalt furnace. This willdetermine exactly when the furnace will begin preheating toyour setpoint temperature. We recommend that you set thetime for at least 2-21/2 hours before you want to beginwork.

1. Press the timer button on the key pad. Theheating elements will shut down at this time. Thewake up time will be displayed in the ElapsedTime display and the wake-up date will bedisplayed in the Percent Loss display.

2. Enter the wake-up date by inputting the monthand then the day. Example: May 16th would beentered as 516. Then press ENTER. The wake-up date is now set.

3. You may now proceed to enter the wake-uptime.

If at any time you wish to disable the timer, press theSTART/STOP button.

Inactivity ModeBy using the hidden key feature with the Timer key, youcan select the Inactivity Mode. This mode allows thefurnace to wake-up at the programmed time and date, butif the user does not press any keys for a period of 4 hours,the unit will shut down and In Ac will be displayed in the

Timer Mode

NoteIf you dont want to enter a wake-update you can bypass this feature bysimply pressing ENTER after you havepressed the timer button in step 1.Bypassing the date automaticallyconverts the timer from aprogrammable 364 day timer to a 24-hour timer. This means that when theprogrammed Time is reached, theunit will begin heating, ignoring thewake-up date. The date needs to beset at 0.00 for this to happen.

NoteThe timer format is European orMilitary time so to enter a wake-uptime of 5:00 a.m. you would input 500and then press ENTER. A wake-uptime of 5:00 p.m. would be entered as1700; then press ENTER. The start uptime and date are now entered.

32

TIMER MODE

chamber temp display. The unit will remain shut down untilthe user presses the START/STOP key. Pressing theSTART/STOP key will set the unit into its normal idle mode.The Inactivity Mode is a valuable feature should the unit beplaced in a remote location and the operator is not able toreturn due to unexpected circumstances such as inclementweather. The unit will remain shut down until the userpresses the START/STOP key.

Interrupting the Timer ModeShould you need to interrupt the Timer mode for anyreason, simply press Start/Stop. The heating elements willreenergize. Depending on how long the furnace has been inTimer mode, some preheating time may be necessarybefore your furnace is ready for use. To return the furnaceto Timer mode again, press the Timer button on the keypad.

33

1. Sample aggregate and sample asphalt cementare preheated to a constant weight in preparationfor the standard ignition method. Failure topreheat samples will introduce inconsistentasphalt content values.

2. Cutback asphalts or slurry seals containingpotentially explosive naphtha, gasoline,Kerosene or other explosive solvents must not beplaced in the tester. Explosion can occur. Thesolvents must be reduced to a safe level prior topreheating in an oven and igniting in the tester.

3. Your tester has a rated load capacity of 5,000grams. Splitting large samples may save timeand produce improved results particularly if yourtest stability threshold is set at a lower value.

4. Back to back testing: Proposed AASHTO andASTM drafts specify Samples can be placed inthe furnace at significantly lower temperaturesince the furnace will quickly heat to the desiredtemperature once the sample begins to burn.For example, this means the furnace temperaturedoes not need to recover to 538C. The heatfrom ignition will typically cause the chambertemperature to recover rapidly. This allows you toincrease your daily test capacity significantly.

5. Your tester automatically compensates for theinitial weight change of the load, caused byheating the load from a low temperature to ahigher chamber temperature. Note that the loadhas not lost any mass at this point; it changesweight because its temperature has increased.Temperature compensation typically ranges from0.1% to 0.25%. A warm HMA sample will beassigned a value of 0.1% or higher. A cold

Methodology and Tester Tips

NoteFor complete Ignition MethodProcedure, contact your Provincial orState D.O.T. or see the A.S. T. M. orAASHTO procedures.

34

sample will be assigned a value near .25%. Test time will be reduced if an HMA sample is warm or hot.

Problem Possible Cause Diagnostic Remedy

AC results too high Sample not dried to a Review standard method Re-dryconstant weight HMA sample preparation

Calibration factor for the Review Calibration Factor Correct or reenteraggregate not entered or Displayis incorrect

Calibration factor is Review Calibration Factor Correct calibration factorincorrect. Display

Entered sample weight Review Sample Weight Correct weight entryincorrectly Display

Chamber temperature Review standard method Rerun calibrationtoo high, causing aggregate calibrating factor procedure factor test perto deteriorate, causing for sample preparation standard methodexcessive weight loss

AC results too low Insufficient air Perform lift test to Oil and clean blowerexchange in chamber ensure a -3.2 to -8.2 gram lift. assembly. Replaceresulting in incomplete blower. Clean exhaustcombustion of sample system. Repeat lift test.

Sample weight and/or Check test tape Correct Calibration Factorcalibration factor readoutentered incorrectly

Basket assembly lodged Correct position of basketagainst chamber or door assemblyresulting in low weight value

METHODOLOGY AND TESTER TIPS

35

Equations Used to DetermineBitumen RatioThe Bitumen Ratio has been added to the Rev. G software.This test result is used in the United States, Canada andEurope. The Bitumen Ratio equation is detailed as follows:

Bitumen Ratio = (Weight Loss/Sample Weight after ignition)x 100 minus temperature compensation,minus correction factor.

The Bitumen Ratio test results are printed in the headerabove the calibrated asphalt content for each test.

Calibrated Asphalt = (Weight Loss/Sample Weight Content x 100 minus

temperature compensation,minus correction factor.

Test Interrupt/Power InterruptIf the power to the furnace is interrupted during an ignitiontest, and then restoredthe furnace will continue the testbut will print the following information on the ticket.

{Results Invalid}

Test Interrupted

Time: XX:XX:XX

The elapsed time will restart at 1 and continue to count up.The software will continue to monitor the weight loss andrecognize the endpoint to end the test.

This feature will prevent smoke from entering the lab shoulda power interrupt occur. Once power has been restored theblower will start up again to maintain air flow through thechamber. This will also prevent the user from prematurelyopening the door.

Software Features

NoteIf you use Bitumen Ratio for your endresults, you must use this factor durngyour mix calibration procedure. Ignorethe calibrated asphalt content number.

36

The power interrupt feature also applies to theprogrammable timer. Should the power go off during thenight while the unit is asleep and then come back on priorto the programmed wake-up time, the software willrecognize the present time and wake-up at the correctprogrammed time.

Auto Shutdown ModeThe software can be toggled between Auto Mode andManual Mode by performing a Hidden Temp Key Routine.In the Auto Mode, the unit will recognize the endpoint, stopthe blower, print the results and then BEEP once every 60seconds until the operator presses the START/STOP key.This will unlock the door and disable the beep.

In the Manual Mode the unit will recognize the endpointand place an asterisk by the endpoint. It will continue to runthe test and beep until the operator presses the START/STOP button.

Positive Calibration FactorSoftware has the ability to accept a positive calibrationfactor. By pressing the calibration factor key twicesimultaneously, then entering your number and pressingENTER, a (-) sign will appear in the percent loss display.The software will now subtract a negative number (sameas adding) from the percent loss. This is necessary whentesting HMA that contains hydrated lime that has beenadded with the oil as an antistrip.

Stability ThresholdEndpoint detection can be adjusted from .01% - .5% of thesample weight. A higher stability threshold can sometimesbe advantageous when burning off samples containingvery soft aggregates. The stability threshold can bechanged by performing a hidden key function using thecalibration factor key, then entering the new number. (SeeHidden Key Routines.)

SOFTWARE FEATURES

NoteIf your test procedure calls foraggregate calibrations to determinethe calibration factor, you will need torun the tester in the Manual Mode.

37

Serial Port Output/OperationThe furnace has a serial output port on the rear of the unit.The port outputs a data string to any computer able toreceive RS232 serial communications. A one-way cable toconnect the computer with the furnace is needed, alongwith software on the computer to collect the data. graphActData Logging and Graphing Software will automaticallycollect and graph data from the computer for you. If you areinterested in the graphACT Data Logging Software, contactKG Systems at (201) 429-9300 or fax them at (201) 429-2298. Order computer cable from Barnstead|Thermolyne oryour Barnstead| Thermolyne distributor. Other software,such as Terminal in Microsoft Windows, can be used tocollect and manipulate the raw data from the furnace. Rawdata collected in this manner can be graphed andmanipulated in a spreadsheet program such as Lotus123.

Sample Data Serial Port OutputOn the next page are two lines of sample data output. Eachline contains the data output of a single second of the testcycle, sampled once every minute. The data output can beeither continuous or just output during a test. To change,see Hidden Key Routines, page 41.

Serial Port Output/Operation

38

Description of Sample DataKey Description1 Test Status (ON/OFF)2 Elapsed Time (minutes)3 Actual Chamber Temperature (C)4 Actual Weight Loss (g)5 Actual Weight Loss (%)6 Actual Filter Temperature (C)7 Chamber Setpoint (C)8 Filter Setpoint (C)9 Sample Weight (g)10 Time (24 hour format)11 Date (M/D/Y) or (D/M/Y)12 Temperature Compensation (%)13 Calibration Factor (%)14 Calibrated Asphalt Content (%)15 Test Stability Threshold (g)16 Stability Indication (+/-)17 Bitumen Ratio

SERIAL PORT OUTPUT /OPERATION

Key 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17ON, 34 552 166.9 5.49 784 538 750 3036 12:03:54 6-11-97 0.09 -2.56 7.96 0.01 - 8.28OFF, 34 552 167.0 5.50 784 538 750 3036 12:03:55 6-11-97 0.09 -2.56 7.97 0.01 + 8.29

Sample Data Output

39

Furnace Error CodesAll errors (unless explicitly noted) will cause the testprocedure to stop. Furnace error codes are displayed in redLED windows located on control panel.

E001 Chamber thermocouple circuit is open. Tip may becracked at weld. The chamber heat may open thecrack by thermal expansion. Replace thermocouple.Resistance of a normal thermocouple is

40

E009 Setpoint is out of range. This is a temporary error toalert you that you have crossed the allowableboundary for the function you are setting. Thefurnace will beep for 3 seconds while displayingthe error, and then return to normal operation. Thesetpoint will revert to its previous value.

E010 Chamber thermocouple leads reversed.Thermocouple is type K. Polarity is coded as red(-) and yellow (+). Polarity must be consistentthroughout the circuit.

E011 Filter thermocouple leads reversed. Thermocoupleis type K. Polarity is coded as red (-) and yellow(+). Polarity must be consistent throughout thecircuit.

E012 Balance not communicating; weight,time and date not received. This may becaused by the balance not beingconfigured correctly. Follow theprocedure on pages 18-21.

Setra Balance Error CodesDisplayed in green Balance indicator window.HHHHHH Exceeds maximum specified load. Remedy:

Reduce loads to specified range.LLLLLL Load does not meet minimum specified

load requirements. Remedy: Increase loadto specified range.

NOCAL Unable to do span calibration (load notwithin 1% of cal weight, or weightunstable).

UnABLE Unable to process command (usually dueto being in improper mode).

ProtEc Calibration protect switch not in thePROTECT position during operation.

REPlug System not calibrated.

OFLO Internal arithmetic overflow.

S Err Processor stack overflow.

In Err Memory indexing error.

EXPLANATION OF ERROR CODES

41

Hidden Keys provide multiple use of the keypad. HiddenKey Procedures typically are used to access infrequentlychanged user variables and infrequently used diagnosticprocedures. The access, procedure, and exit are detailedunder each key procedure. The furnace must be in the(non-programmable) mode to access the Hidden Keys.

0 Key-DiagnosticsAccess: Depress the Power Switch to ON while `

simultaneously depressing the 0 key.

Procedure: Enters the diagnostic procedure forfactory testing. The printout is typically filedwith the Operation Manual.

Exit: Depress Power Switch to OFF andthen ON to return to normal operation.

1 Key-Printout Paper Saver:

Access: Depress Power Switch to ON whiledepressing the 1 key simultaneously.

Procedure: Chamber temperature display PRN and thePercent Loss display will toggle ON orOFF as the access procedure isrepeated. The new mode will be displayedfor three seconds and then the furnace willreturn to normal operation.

Exit: Automatic2 Key-Default

Access: Depress the 2 key while simultaneouslydepressing Power Switch to ON.

Procedure: DEF will be displayed for three seconds toindicate variables have been reset tofactory values. The furnace will return tonormal operation. Defaulting to factoryvalues is a useful diagnostic tool as acomparison of current values vs. factoryvalues can be made within minutes. Valuescan be printed by depressing ENTERwhile simultaneously depressing the Power

Hidden Key Routines

42

Switch to the ON position.

Exit: Automatic

3 Key-Chamber Calibration Procedure

Equipment 1 ea. Digital Pyrometer with PenetrationNeeded: Probe, Sensor NIST Traceable. (PM20700

Pyrometer with TC405X4 PenetrationProbe).

Setup: Calibration consists of inserting a sensorpenetrating through the covered stainlesssteel tube located adjacently to the controlthermocouple. Entry is at the top centerrear of furnace. The penetrating probe isneeded to penetrate through the softinsulation. Probe insertion is at the samedepth of the chamber control thermocouple.Cover probe entry tube after the calibrationprocedure has been completed. Do notplace pyrometer on top of hot furnace. Afterinserting the test thermocouple penetrationprobe, set furnace chamber and filter at 538C or standard method specified temperature.Allow furnace to stabilize at setpoint in the idlemode. The maximum offset allowed beforecalibration is required is 50C.

Access: Depress 3 key while simultaneouslydepressing power switch to ON.

Procedure: CHBR CAL will be displayed in the PercentLoss and Elapsed Time windows respectively.The Chamber Temperature window will displaythe actual chamber temperature which shouldbe at or near setpoint temperature. Allow thefurnace to stabilize at setpoint.

Enter the temperature displayed in C by thedigital pyrometer by using the keypad. PressENTER. The new offset value will be usedand the entered temperature will be displayed.The entered temperature is the temporarysetpoint.

HIDDEN KEY ROUTINES

43

The original setpoint will return upon exiting.The software has calculated and saved thenew offset value which will apply to allsetpoints throughout the operating range.

Exit: Depress Power Switch to OFF and thenON to return furnace to normal use. Removesensor probe and cover entry tube.

4 Key-Provides Entry to Balance Menus

Access: Depress 4 key while simultaneouslydepressing Power Switch to ON.

Procedure: BAL will display in Chamber Temperaturewindow. CAL will display in Percent Losswindow. Entry allows user to change time anddate settings, review and adjust balanceinputs, and calibrate balance. These topicsare detailed under the Balance Calibrationinstructions. (See pages 18-23.)

Exit: Depress Power Switch OFF and then ONto return furnace to normal use.

5 Key-Filter Temperature Adjustments

Access: Depress 5 key while simultaneouslydepressing the Power Switch to ON.

Procedure: Adjustment range is 0-900C. Factory setpointis 750C. Chamber Temperature displayscurrent setpoint. Percent Loss windowdisplays FIL. Elapsed Time window displaysSP for setpoint. Use the keypad to change thedisplay to the new setpoint value. DepressENTER promptly. This new setpoint valuewill be displayed.

Exit: Depress Power Switch to OFF and thenON to return furnace to normal operation.

6 Key-Disables Error Codes:

Access: Depress 6 key while simultaneously switchingthe Power Switch to ON.

HIDDEN KEY ROUTINES

44

Procedure: ERR will be displayed in the ChamberTemperature window. OFF will be displayedin the Percent Loss window. The furnace willautomatically return to normal operation withinfive seconds with the ERR codes inactivated.

ERR codes are defeated to perform diagnosticprocedures as to temporarily ensure continuedfurnace operation in the event of a false errorcode.

Exit: Depress the Power Switch to OFF and thenON to return the furnace to normal operationwith activated error codes.

7 Key-Displays Actual Filter and ChamberTemperature:

Access: Depress the 7 key while simultaneouslydepressing the Power Switch to ON.

Procedure: Chamber Temperature will display actualtemperature. The Percent Loss displays actualfilter temperature. You can compare actualchamber and filter temperatures with setpointto assess the need for the thermocouple orelement replacement or re-calibration.

Exit: Depress the Power Switch to OFF and thenON to return the furnace to normal operation.

8 Key-Serial Port Output Adjustment

Access: Depress the 8 Key while simultaneouslydepressing the Power Switch to ON.

Procedure: SPC or SPn will display in the ChamberTemperature window for three seconds. SPCprints the serial output continuously. SPnprints the serial output only when the furnaceis in the program mode. Accessing toggles themode between SPC and SPn. The displayedmode is the active mode. Default is the SPCmode.

HIDDEN KEY ROUTINES

45

Exit: Automatically returns to manual operationwithin three seconds.

9 Key-Disables Beep

Access: Depress the 9 Key while simultaneouslydepressing the Power Switch to ON.

Procedure: The Chamber Temperature will display BEEP.The Percent Loss window will display ON orOFF. The mode condition will display forthree seconds. Accessing toggles the modebetween ON and OFF. The displayedmode is the active mode. The default mode isBEEP ON.

The beep should only be deactivated whenthe tester is used in the Manual Test Mode.The beeper should always remain activewhen the tester is in Auto Mode.

The option to inactivate the beeper is usefulfor raw aggregate calibration when minutelosses may cause the endpoint beeps toactivate prematurely before the procedure hasbeen completed. The key press beep is notdisabled in the BEEP OFF mode.

Weight Key-Prints Out Balance Variables

Access: Depress the weight key while simultaneouslydepressing the Power Switch to ON.

Procedure: The Percent Loss Window will display SCAL.The Elapsed Time window will display LIS.The printout will generate automatically uponentering the printout mode. See example offactory printout for balance variables on page24.

Exit: The furnace will automatically return to normaloperation after the printout is generated.

HIDDEN KEY ROUTINES

46

Enter Key-Prints Out User Variables

Access: Depress the ENTER Key while simultaneouslydepressing the Power Switch to ON.

Procedure: PRN will display in the Percent Loss window.USR will display in the Elapsed Time window.The printout will generate automatically uponentering the printout mode.

Exit: The furnace will automatically return to normaloperation after the printout is generated.

Calibration Factor Key-Adjust or Check TestStability Threshold of a Test

Access: Depress the Calibration Factor Key whilesimultaneously depressing the Power Switchto ON.

Procedure: The stability threshold setting will be displayedin the Percent Loss window. The Elapsed Timewindow will display FLN. The value options are0.01 - 0.5%. Enter the new value via keypad.Observe the Percent Loss window as the newvalue is entered. The new value must beentered and the ENTRY key must bedepressed within five seconds.

ASTM Draft 6 specifies test endpointcompletion when the measured mass lossdoes not exceed 0.01% over threeconsecutive one minute periods. AASHTOspecifies endpoint completion when the massloss does not exceed 0.02% over twoconsecutive one minute periods. The teststability threshold value defines the endpoint.The value must match the standardspecification you are applying. The teststability value is printed on the User VariablePrintout. See Hidden Key ENTER. An exampleof the printout is depicted on page 24.

Exit: Depress Power Switch to OFF and then ONto return furnace to normal operation.

HIDDEN KEY ROUTINES

ON/ENTER printout example

ON/WEIGHT printout example

47

Temp Key - Toggles from Auto Program Switching Idleto Manual Program Switching to Idle at Endpoint

Access: Depress TEMP key while simultaneouslydepressing the Power Switch to ON.

Procedure: AU appears in the Chamber Temp display. ThePercent Loss displays either ON or OFF.Repeat ACCESS if OFF is displayed.Repeating access changes the display to AUON. You are now in the Auto ProgramSwitching to Idle mode. Repeat ACCESSagain to return to the Manual ProgramSwitching to Idle mode.

Auto Program Switching to Idle can increasethe number of tests run per day. Theoperators monitoring time is eliminated as thetest results automatically print out at endpoint.The Manual Program Switching to endpoint isstill available in the event continuous runningis required after endpoint.

Exit: AU ON or OFF is displayed forapproximately five seconds. The furnaceautomatically returns to idle.

Timer Key - Disables Inactivity CheckAccess: Depress theTime key while simultaneously

depressing the Power switch to ON.

Procedure: The chamber temperature will display INAC. The Percent Loss window will displayON or OFF. The mode condition will displayfor three seonds. Accessing toggles the modebetween ON and OFF. The displayed modeis the active mode.

Active Keys

These keys activate a function when depressed. Thefurnace must be in the idle (non-programmable) mode.

HIDDEN KEY ROUTINES

48

0 Key-Tares the Balance

Access: Depress 0 key. The balance will automaticallytare to 0 grams in the balance display.

Procedure: This mode is useful to perform the lift test, asthe balance must be tared before conductingtest. See Glossary.

The weight of the loaded basket assembly canbe rechecked if the balance is tared prior toloading.

Exit: Automatic at ACCESS.

Enter Key-Duplicates Header Test Results

Access: Depress the ENTER key.

Procedure: The header test results will print out for lasttest if no other key functions have beenperformed since printing of the last test results.The power switch must not be switched OFFand ON after the original test report isgenerated.

This feature provides as many header copiesof the last test results as needed by theoperator.

Exit: Automatic upon completion of printout.

HIDDEN KEY ROUTINES

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Refractory ceramic materials are located in the door, and inthe chamber of the furnace. Tests performed by themanufacturer indicate that there is no significant risk ofexposure to dust or respirable refractory ceramic fiberresulting from operation of the equipment under normalconditions. However, there may be a risk of exposure torespirable refractory ceramic dust or fiber when repairing ormaintaining the insulating materials, or when otherwisedisturbing the materials in a manner which causes releaseof dust or fibers therefrom. Through the use of properhandling procedures you can work safely with theseinsulating materials and minimize any exposure.Accordingly, before you repair or replace any insulatingmaterials, or perform any other servicing on this productwhich could disturb or cause exposure to dust frominsulating materials, you should consult the appropriateMaterial Safety Data Sheets (MSDSs) for such productswith respect to proper handling and appropriate protectiveequipment. For additional MSDSs, or additional informationconcerning the handling of refractory ceramic products,please contact the Customer ServiceDepartment of Barnstead|Thermolyne or Barnstead|Thermolyne distributor.

Element Plate Construction Useand CareYour tester contains five element refractory platescontaining special helical coiled element embedded in therefractory. The proprietary element design protects theelement wire from harmful asphalt ignition fumes, arrestscoil expansion and contraction and protects the coils frommechanical damage. The filter element heats the ceramicfilter and is controlled by a separate electronic controller.The sides, top, and bottom elements heat the chamber.

It is normal for the refractory plates to develop hairlinecracks in the refractory plates. This does not necessitateelement plate replacement if the mechanical strength is notcompromised.

Periodically fire the chamber at 650C for two hours in theidle mode to clean element plates. Vacuum chamber flooras needed.

Preventive Maintenance andServicing

WarningThis furnace contains refractoryceramic insulation which can producerespirable fibers and dust whenhandled. These fibers can causeirritation and can aggravate preexistingrespiratory disease. The InternationalAgency for Research on Cancer(IARC) has classified refractoryceramic fiber as possibly carcinogenic.After service refractory ceramic fiberdust may contain crystalline silica,which may cause lung damage(silicosis) and which has been classedby IARC as a probable carcinogen.(See MSDS, p. 68.)

Refer servicing to qualified personnel.

Hot SurfaceAllow the furnace to cool to roomtemperature before performing anymaintenance or servicing. HotSurface. Avoid Contact.

WarningTo avoid electrical shock, this furnacemust always be disconnected from thepower supply prior to maintenance andservice.

Perform only maintenance described inthis manual. Contact an authorizeddealer or our factory for parts andassistance.

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PREVENTIVE MAINTENANCE AND SERVICING

Your tester requires blower maintenance which consists ofcleaning and oiling the motor about every six months or ifthe lift test results indicate a decline in blower efficiency.This service requires detaching the exhaust duct, removingthe top cover and fume hood. The motor is fastened to therear of the fume hood. Place one drop of Anderol HighTemperature Lubricant (included in accessory kit), into thesmall oil ports located on the blower motor. Locate the testerwhere adequate space for servicing is available. Excessiveair leakage around the door insulation can also reduce liftvalues. The remedy is to adjust the door fit or replace doorinsulation. Door fit adjustment is performed by loosening thetop and bottom hinge screws. Adjust the door and refasten.

Door lock adjustment may also be required to ensure properdoor seal. The latch hook on the door, hooks the latch pin inthe closed position. The latch pin is adjustable. The twoPhillips screws located above the latch pin port tighten thedoors fit when turned counter clockwise. One screw shouldbe turned a half turn followed by turning the second screw ahalf turn. This adjustment procedure will ensure proper latchpin position and prevent binding.

The blower assembly consists of the wheel housing, coolingfan bracket and motor. A 2 wide paint brush with a vacuumcleaner works nicely to clean the assembly, baffle plates,ceramic vent tubes and flame deflectors. We recommendwearing glasses.

To Replace a Chamber Heating Element1. Disconnect furnace from power supply. (See

parts list for normal cold resistance values.)

2. Remove the back terminal cover of the furnace.(Note placement and connections of wires.)

3. Loosen the screws and nuts on the terminals ofthe element to be replaced.

4. Open the door.

5. Remove the hearth tray and the ceramicsupporting posts.

6. Pull the defective element out.

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7. Slide the new element into place, threading theleads through the insulating porcelain bushingon the back of the furnace.

8. Cut off any excess lead wire. Reinstall terminalconnections and tighten screws and nutssecurely.

9. Replace the ceramic supporting posts and thehearth tray.

10. Replace the back terminal cover.

11. Reconnect furnace to power supply.

12. Test operation of furnace.

To Replace a Filter Heating Element1. Disconnect the furnace from the power

supply.(See parts list for normal cold resistancevalue.)

2. Remove the back terminal cover of the furnace.(Note placement and connections of wires.)

3. Loosen the screws and nuts on the terminals ofthe filter element. Remove the filterthermocouple.

4. Remove exhaust tubing, remove top cover andfume hood.

5. Open the door of furnace, remove the (4) screwsretaining the cover above the door.

6. Remove the fume hood retaining brackets andremove all screws which are holding the topcover plate onto the furnace.

7. Remove top cover plate, blanket insulation, andtop piece of vacuum formed insulation. Theelement will be exposed. Remove the filterelement. Inspect the filter.

8. If filter is OK, then install the new element,threading leads through the insulation, porcelainbushings and terminals on back of furnace.

9. Replace the insulation, top cover and frontcover.


CautionMake sure to align the five holes in theinsulation to the top cover plate.

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10. Tighten screws and nuts on the elementterminals, trim the excess wire from the elementleads.

11. Replace the back terminal cover, fume hood,fume hood retaining brackets, ceramic posts,hearth plate, top cover, and exhaust.

12. Reconnect furnace to power supply.


To Replace a Type K Chamber Thermocouple1. Disconnect furnace from power supply. (See

Replacement Parts list for normal coldresistance value).

2. Remove the back terminal cover of the furnace.(Note placement and connection of T/C leadwires).

3. Remove the screws on the chamberthermocouple terminals and disconnect thewires.

4. Remove the clamp retaining the thermocouple.

5. Pull the thermocouple straight back.

6. Insert the new thermocouple into the furnace andconnect the leads to the terminal block, matchingthe wire colors with the incoming wires.

7. Secure connections with screws removed in Step3.

8. Replace the back terminal cover.

9. Reconnect the furnace to power supply.


To Replace a Type K Filter Thermocouple1. Disconnect furnace from power supply. (See

Replacement Parts list for normal coldresistance value.)

2. Remove the back terminal cover of the furnace.(Note placement and connection of T/C leadwires.)


NoteThe thermocouple circuit consists ofthe thermocouple and thermocoupleextension lead wires. Polarity plus toplus and minus to minus must bemaintained in the circuit. Reversinglead wire polarity, thermocouple leadwires touching one another orgrounding to case will cause thechamber temperature to exceed thesetpoint temperature and could causeelement failure. The actual displayedtemperature will read on the low sideof setpoint temperature.

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3. Remove the screws on the filter thermocoupleterminals and disconnect the filter thermocouplewires.

4. Remove the clamp retaining the thermocouple.

5. Pull the thermocouple straight back.

6. Insert the new thermocouple into the case.

7. Replace the clamp securing the thermocouple.

8. Connect the leads to the terminal block,matching the wire colors with the incoming wires.

9. Replace the back terminal cover on the furnace.

10. Reconnect the furnace to the power supply.

11. Test the operation of the furnace.

To Replace a Solid State Relay

NCAT 1087 MANUAL.pdf

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