ATS PAV4 Instruction Manual Download

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MAN - PAV4 - REV: Original

PAV4

Pressure Aging Vessel 4

INSTRUCTION MANUAL

This manual contains important operating and safety information. Carefully read and understand the

contents of this manual prior to the operation of this equipment.

www.atspa.com

Summary of Contents for PAV4

Page 1: ...PAV4 Pressure Aging Vessel 4 INSTRUCTION MANUAL This manual contains important operating and safety information Carefully read and understand the contents of this manual prior to the operation of this equipment www atspa com ...

Page 2: ... not represent a commitment on the part of Applied Test Systems ATS 154 East Brook Lane Butler PA 16002 USA Telephone 1 724 283 1212 For assistance with set up or operation contact the ATS service department Please have this manual and product serial number available when you call Copyright Applied Test Systems 2019 ...

Page 3: ... Overview 5 C 1 General Description 5 C 2 Vessel Certification 5 C 3 Specifications 5 C 4 Environmental Conditions 6 D Installation 7 D 1 Unpacking 7 D 2 Installation 7 D 3 Pan Holder Leveling 7 D 4 Air and Power Connections 8 D 5 Regulator Connections 9 E Software Overview 11 E 1 Software Screen Map 11 E 2 Main Screen 11 Preheat Button 12 Age Cycle Button 12 End Stop Button 12 Shut Off Button 12 ...

Page 4: ...17 Settings Language Data and Alarm Buttons 17 Done Button 17 E 4 Language Screen 17 E 5 Settings Screen 18 Pressure Temp Window 18 Age Time 19 Age Temp 19 Age Pressure 19 Pressure Alarm Time 19 Recovery Limit 19 Age Limit 19 Temperature Drop Down Field 19 Pressure Drop Down Field 19 Shutoff Heater at End of Test Checkbox 19 Stop Test on all Errors Checkbox 20 Current Time 20 Preheat Delay 20 Done...

Page 5: ...ature Does Not Recover to Setpoint 28 H 2 Troubleshooting the PAV Controller 28 H 3 Reattaching the Flow Adjust Valve 29 H 4 New HMI Software 30 H 5 New PLC Software 32 H 6 New Temperature Controller Software 32 I Maintenance 33 I 1 Preventative Maintenance 33 I 2 Changing Fuses 33 I 3 Spare Parts 33 Consumables 33 Accessories 34 Spare Parts 35 Appendix A Warranty 36 Appendix B Image Glossary 37 ...

Page 6: ...gainst defective parts and workmanship for one full year from the date of shipment Please see APPENDIX A of this manual for complete details on the warranty A 3 After Sale Support If there are any questions concerning the operation of the unit or software contact the ATS Service Department at 1 724 283 1212 Before calling please obtain the software revision number from the View Screen and the seri...

Page 7: ...Department at 1 724 283 1212 In addition to the safety warnings listed on the equipment warnings are posted throughout this manual Read and follow these important instructions Failure to observe these instructions can result in permanent damage to the unit significant property damage personal injury or death Read Operators Manual General Danger Protective Earth Ground Burn Hazard Hot Surface Elect...

Page 8: ...l code requirements WARNING Be careful when working with equipment at elevated temperatures In order to prevent burns wear protective clothing WARNING Use caution when opening the oven lid Electrically heated equipment can cause severe burns WARNING Allow adequate time to relieve all the pressure from the vessel before opening the oven lid and the pressure vessel lid Any unrelieved pressure can ca...

Page 9: ...UTION Closing the flow adjust valve when the PAV is in operation will cause damage to the valve CAUTION All supporting and contacting surfaces must be non flammable Do not allow flammable materials to contact the shell CAUTION If an emergency shutdown needs to be performed place ON OFF switch in an OFF position Unit will depressurize automatically within 10 15 minutes CAUTION Do not overflow PAV p...

Page 10: ... holder C 2 Vessel Certification ASME Code Unless otherwise noted the PAV is designed fabricated inspected tested and stamped in accordance with the ASME Boiler and Pressure Code Section VIII and a maximum temperature of 110 C 121 C The ASME Boiler and Pressure Vessel Code is an Internationally Recognized Standard Contact ATS for the vessel certificate U IA Report and CE Declaration of Conformity ...

Page 11: ...ower loss solenoid valve will open and release any pressure in the PAV vessel C 4 Environmental Conditions Operation of the ATS Pressure Aging Vessel involves use of high temperatures and contents being contained at high pressure The location and placement of the PAV should always take these elements into consideration to ensure a safe working environment The PAV is meant for use in laboratory fac...

Page 12: ...e shell 3 Level the PAV by adjusting the screws on the four feet 4 Inspect the O ring seal Make sure it is clean and lightly coated with silicone grease If the O ring appears to be worn or damaged contact ATS D 3 Pan Holder Leveling 1 Once the PAV is in place you will need to verify that the leveling ring is evenly balanced The leveling ring is removed prior to shipment and needs to be checked on ...

Page 13: ...e Power requirements are 230 240 VAC 5 V 10 amp single phase 50 60 Hz CAUTION The PAV requires a minimum of 230 VAC to operate correctly Check the supply voltage to ensure it is 230 240 VAC If the supply voltage is less than 230 VAC a Step Up or Buck Boost transformer can be supplied to provide the proper operating voltages Contact ATS Be prepared to provide the ATS Service representative with inf...

Page 14: ...ols the rate at which the PAV depressurizes When the flow adjust valve is set at the recommended setting the PAV will depressurize at optimal rate The unit will have a sticker see below with the correct values Use the value marked Flow Adj NOTE See Section I Maintenance for information on what to do if the flow adjust valve detaches D 5 Regulator Connections 1 Secure the air connection to the air ...

Page 15: ...nnections Connect the male end of the hose to the female connection on the PAV by sliding the female connection towards the PAV connecting the hose and releasing the slide 4 Verify that all connections are tightly sealed by applying soapy water on the connections and turning on the air If suds appear apply more compound or tape to seal the leak Figures D 5 D 7 Regulator Connections ...

Page 16: ...Software Overview E 1 Software Screen Map Figure E 1 shows the PAV s software screens E 2 Main Screen Figure E 2 below shows the Main Screen which displays when the PAV is started It allows you to setup and run age Figure E 1 PAV Software Screen Map ...

Page 17: ...d to start the recovery for the age cycle End Stop Button Used to tell the system to finish the cycle It can also be used anytime the PAV is in cycle to stop the age cycle When the age cycle has finished this button will blink to show the cycle is finished If pressed while in an aging cycle a pop up dialog will ask if you are sure you wish to end the current test Shut Off Button Can be used at any...

Page 18: ...e when the system is in aging cycle state Note the Remaining Time being displayed This will show up for the Preheat Delay and the Aging Cycle states and will display the time remaining for this part of the cycle Near the top of the display is a status bar that will show the current state of the oven cycle Below are the different states in the order that they usually run Off State Displayed when th...

Page 19: ... Cycle button has been pressed The system will recover to the cycle temperature When it gets within the pressuere temperature window it will start to pressurize It will stay in this state until the vessel is at cycle temperature and pressure Aging Cycle State Displays when the vessel is at cycle temperature and pressure the age cycle starts It will stay in this state holding temperature and pressu...

Page 20: ...Preheat Delay State Displays when the system has been set up to start the preheat automatically after a time delay You can think of this like a coffee timer Below are the Graph and Data screens that are available when you press the Graph button on the Main Screen It allows you to view the graph and data of the currently running age cycle Figure E 9 Aging Finished State Figure E 10 Preheat Delay St...

Page 21: ...NOTE When in the graph view pressing either the min or max value of either temperature or pressure will allow you to adjust the scale values or graph scaling E 3 View Screen Figure E 13 below shows the View Screen It is shown anytime the View button is pressed on the Main Screen It allows access to the rest of the screens in the system If the system is not idle this button is not visible and you w...

Page 22: ...d Standardize Button Will not be displayed until the correct ID and Password has been entered Once it is displayed pressing it will go to the standardize screen Default ID 2 Password 222222 Passwords Button Will not be displayed until the correct ID and Password has been entered Once it is displayed pressing it will go to the password screen Default ID 3 Password 333333 Settings Language Data and ...

Page 23: ... E 5 Settings Screen Figure E 15 below shows the Settings Screen which is displayed when the Settings button is pressed on the View screen It allows set up of the system Pressure Temp Window Figure E 14 Language Screen Figure E 15 Settings Screen ...

Page 24: ...ure Alarm Time The amount of time that the system has to reach the age pressure once the system starts to pressurize If it does not reach pressure in this time a pressure error is set Recovery Limit Sets the maximum recovery error time that the system may have before a recovery error is set Age Limit Sets the maximum age error time that the system may have before an age error is set Temperature Dr...

Page 25: ...llow button The button will light to show that a delay has been set The delay button is a toggle switch so to turn off a delay that has been started just press the button again The status of the system will show Preheat Delay when it is active and the remaining time before preheat start is shown Done Button The Done button will return you to the View Screen E 6 Alarm Screen Figure E 16 shows the A...

Page 26: ...his field to select one to look at Backup All to USB Allows the operator to backup all the log files currently on the system to a USB flash drive These will be csv data log files Note there is a checkbox on the standardization screen to delete all log files after back up If it is checked all log file files will be deleted after they are backed up to the USB drive Done Button Will return you to the...

Page 27: ...riginal E Software Overview 22 NOTE When in the graph window pressing either the min or max value of either temperature or pressure will allow you to adjust the scale values Figure E 17 Data Screen Figure E 18 Graph ...

Page 28: ... 4 Verify that all the parameters are set correctly for your application 5 Select Done to return to the View Screen 6 Select Done to return to the Main Screen 7 Open the oven lid by unlatching the latches Unbolt see note below and open the vessel lid Insert an EMPTY pan holder into the PAV vessel NOTE DO NOT load any samples into the PAV at this time NOTE Bolt 1 in the diagram is a pivot bolt and ...

Page 29: ...into the sample holder even if there are not ten samples to age 13 Quickly and carefully return the sample holder to the PAV The vessel temperature will decrease when the oven and vessel lids are open To avoid a long temperature recovery attempt to load the PAV and secure the vessel and oven lids as quickly and as safely as possible 14 Close the vessel lid and secure the bolts according to the dia...

Page 30: ...ress the End Stop button CAUTION When the age cycle finishes there is still pressure in the vessel This has a slow linear bleed down and will take about 15 minutes Check the current pressure reading and make sure the vessel is NOT pressurized before you attempt to remove samples ...

Page 31: ...proble slide the PAV lid closed Use a small wrench or popsicle stick to keep the lid from pinching the wire on the temperature probe DO NOT BOLT THE LID DOWN 3 Set up the setpoint and start the PAV 4 Verify that the temperature display on the thermometer matches the temperature display on the PAV Allow temperature to reach setpoint and stabilize for one hour 5 Note any difference and call ATS for ...

Page 32: ...e pressure to the PAV Allow pressure to reach 2 1 0 1 MPa and stabilize for fifteen minutes 4 Verify that the display on the pressure gage matches the displayed pressure on the PAV display 5 Note any difference and call ATS for calibration if the difference falls out of specification NOTE It is best to have the PAV setpoint at a low temperature NOTE Do not verify temperature and pressure at the sa...

Page 33: ...ving 230V 240V of power NO YES You will need a transformer Call ATS for a quote Did you wait till the PAV was at setpoint to load samples into the PAV YES NO Do not load samples into the PAV until setpoint is reached and PAV prompts it Are you preheating your samples above the aging temperature YES NO Only preheat your samples to the set point of the PAV using your lab oven Are you leaving the ves...

Page 34: ...red to begin the automatic aging process Do NOT wait for temperature of the PAV to recover to the setpoint before pressing Age button 3 Do NOT preheat samples prior to placing in PAV to a temperature higher than the temperature to be used to age the samples in the PAV It is recommended to use room temperature samples The PAV will preheat the samples according to specification H 3 Reattaching the F...

Page 35: ...p the adjustment knob with zero at 12 o clock and insert over the brass collar and to the last line of the valve body Using the 1 16 in hex wrench insert into the hole as shown in Figure H 4 and tighten 6 Turn the valve slowly counter clockwise to open Each full rotation should equal one line on the barrel Rotate the knob to the value recorded on the calibration sticker If there is no value on the...

Page 36: ... up menu will appear prompting for a password Using the keyboard displayed on the screen Figure H 6 enter 111111 Check the box that indicates Download Project files and uncheck the boxes that indicate Clear History files and Download History files and select OK 5 Next will appear 2 subdirectories pccard and usbdisk Click usbdisk select disk_a_1 and click OK Figure H 5 Pop Up Menu Figure H 6 Second...

Page 37: ...rom time to time a new software version may come out for the PLC If you need a new version or you need to reload a version please contact ATS service for help H 6 New Temperature Controller Software From time to time a new software version may come out for the temperature controller If you need a new version or you need to reload a version please contact ATS service for he ...

Page 38: ...located in the pressure vessel flange Damaged or worn O rings should be replaced with the same material I 2 Changing Fuses 1 Control Circuit Fuse FU1 FU2 The control circuit fuse is a 2 amp 250 volt 1 4 x 1 1 4 BUssmann MDC or equivalent fuse 2 Heater Circuit Fuse FU3 FU4 The heater circuit fuse is a 10 amp 250 volt BUssman GBB or equivalent fuse I 3 Spare Parts Some parts are supplied from outsid...

Page 39: ...ltages PAV VER KIT PAV Verification Kit Includes calibration block thermometric device and pressure gage PAV VER KIT NIST NIST PAV Verification Kit Includes calibration block NIST certified thermometric device and NIST certified pressure gage PAV STAND PAV Steel Stand Stand for PAV PAV CART Hydrolic Lift Cart for easy height adjustment of the PAV PAV LEVEL Level with paralell bar 101521 RTD Thermo...

Page 40: ... for use in Europe PAV SS REGULATOR Single Stage Regulator PAV WRENCH Wrench Hex Socket 1 2 In Drive PAV1148 Leveling Ring 4 8310 Rv 2 It1 PAV9012 Tool Pan Handling PAV9015 Adapter CGA PAV9016 Wrench Hex Socket 1 2In Drive PAV9017 Wrench Allen 1 8 Inch PAV9020 Hose High Pressure Assy PAV PAN HOLDER PAV Specimen Rack ...

Page 41: ...duct must be returned to the Applied Test Systems factory or an authorized repair center Applied Test Systems shall not be liable for any labor transportation or installation costs that may arise in connection with the product or return To obtain warranty service 1 Applied Test Systems must be promptly notified in writing of the defect 2 Upon receipt of written authorization said defective equipme...

Page 42: ...inished State 14 Figure E 10 Preheat Delay State 14 Figure E 11 Graph Screen 14 Figure E 12 Data Screen 14 Figure E 13 View Screen 15 Figure E 14 Language Screen 17 Figure E 15 Settings Screen 17 Figure E 16 Alarm Screen 20 Figure E 17 Data Screen 21 Figure E 18 Graph 21 Figure F 1 Bolt 1 22 Figure F 1 Bolt 1 23 Figure G 1 Temperature Probe inside Calibration Block 25 Figure G 2 Inside of PAV 25 F...

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