Barnstead International Thermolyne 859 Series Service Manual Download

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NSTALLATION

Summary of Contents for Thermolyne 859 Series

Page 1: ...NCAT Asphalt Content Furnace Service Manual LT1275X3 2 13 04...

Page 2: ...s 14 OHAUS Balance 15 Installation 15 Balance Control Port Hole Location 17 OHAUS Time and Date Set Procedure 18 Resetting the User Variables of an OHAUS Balance 20 OHAUS Balance Calibration 25 SETRA...

Page 3: ...Procedure 81 Removal of the Control Assembly Bottom Section in the 1087 and 1275 Series NCAT 81 1087 Series Back Wall Insulation Removal 88 Heating Elements 89 Element Part Numbers and Cold Resistanc...

Page 4: ...4...

Page 5: ...Auburn University The NCAT furnace was designed as an improvement over the existing solvent method of determining the binder con tent in asphalt paving materials Why Test Asphalt Hot mix asphalt used...

Page 6: ...t away and only stones remain The software within the unit then calculates the percent of binder within the asphalt mix All of this is included on a paper printout by a small built in strip recorder s...

Page 7: ...wired either directly through a conduit system or by a customer supplied power cord and plug Electrical wiring should conform to local electrical code requirements Please consult with a certified ele...

Page 8: ...ramic Support Tubes Parts Shipped in Accessory Box Located on top of unit not pictured PHX4 Hearth Plate 2 FZX47 Fuses 2 FZX53 Fuses 2 FZX61 Fuses ME859X1 Balance LT1275X1 Manual Barnstead Internation...

Page 9: ...lt with a certified electrician to have the NCAT hardwired or an appropriate power cord and receptacle installed in your facility Electricians will ensure compatibility among furnace spec ifications p...

Page 10: ...aust tubing less than 3 inches in diameter Do not use galvanized tin tubing or double wall tin tubing Do not connect the NCAT exhaust port directly to an external fan with a rating of more than 60 CFM...

Page 11: ...11 INSTALLATION...

Page 12: ...12 INSTALLATION...

Page 13: ...load cell and on the mated display board The SETRA balance does not contain the numerous user variables found in the OHAUS making functions such as resetting the time or date and calibrating the SETRA...

Page 14: ...gular fuse holder cap is located as part of the power entry module The cap also has voltage markings on each side The side facing towards the top of the balance is how the holder cap should be posi ti...

Page 15: ...four aluminum rods The balance will be supported by this table Vacuum the table if dust etc appear on it 4 Mount the platform support plate on the bal ance Note the four pins on the support plate The...

Page 16: ...ugh the tube ports located in the bottom of the furnace chamber Adjust the position of the balance until the four ceramic support tubes are seated on the appropriate pins on the balance plate Finely a...

Page 17: ...d tool or paper clip to access balance keys through the port holes in the control panel Reference the sketch of the control panel for location identification of balance control port holes which will n...

Page 18: ...with microprocessor in the NCAT cor rectly 1 Power down the NCAT furnace using the green power switch Press and the hold the number 4 key on the keypad While holding down the 4 key power up the NCAT u...

Page 19: ...Set is displayed 16 Press the MODE button End Time will be dis played 17 Press the ON button Time will be displayed again 18 Press the MODE button Date will be dis played 19 Press the ON button Type...

Page 20: ...isplayed 34 Press the MODE button until End Menu is dis played 35 Press the ON button The display will revert to displaying the current sample weight 36 Power down the NCAT and power back up using the...

Page 21: ...done when you hear a short train of beeps 7 Press the MODE button AL Averaging Level will be displayed Select this by pressing ON This will display AL 1 The correct value is AL3 In order to change the...

Page 22: ...n will display the time that is entered into the balance If the time is incor rect it may be changed by pressing the MODE button to cycle through the hours Once the correct hour is displayed press the...

Page 23: ...l take you back to the setup mode 28 Press the MODE button Print will be dis played 29 Press the ON button to select Reset will be displayed 30 Press the ON button Yes will be displayed 31 Press the O...

Page 24: ...Repeatedly press the MODE button until the word Time is displayed Press the ON button to enter this menu Change setting to On by pressing the MODE button Press the ON button to approve the setting Tim...

Page 25: ...of the balance in either of these two modes is not necessary 1 Power down the NCAT allowing the unit to cool to ambient chamber temperature 2 Open the furnace door and remove the hearth plate setting...

Page 26: ...required mass on the calibration plate 11 Press the ON button C displayed while the balance calibrates NOTE DO NOT DISTURB THE BALANCE WHEN C IS DISPLAYED 12 Display will automatically indicate S fol...

Page 27: ...furnace Disconnect wire harnesses 6 Secure the support plate with 4 screws on SETRA balance 7 Set the SETRA balance load cell in the control section of the furnace 8 Connect the 10 pin gray ribbon ca...

Page 28: ...osts are not in contact with any part of the NCAT chamber section 12 Set the load plate back on the 4 ceramic support posts in the chamber Make sure the load plate does not come in contact with the si...

Page 29: ...ed tool or paper clip to access balance keys through the port holes in the control panel Reference the sketch of the control panel for location identification of balance control port holes which will...

Page 30: ...roprocessor in the NCAT correctly To Set the Time 1 Turn the green power switch on the furnace control panel to the OFF position 2 Press hold the 4 key while turning the green power switch to the ON p...

Page 31: ...evice such as straightened paper clip Note balance control port holes in control panel sketch 4 Press hold the balance ENTER key with a small device such as straightened paper clip Note balance contro...

Page 32: ...to reset the parameters inside the bal ance which are not user accessible The TIME DATE and CALIBRATION are not affected 1 Turn the green power switch on the furnace con trol panel to the OFF positio...

Page 33: ...remain open during the entire calibration procedure and the chamber must be at ambient temperature 3 Make certain the chamber ceramic hearth plate is centered on supports posts and free of debris 4 P...

Page 34: ...T traceable on the ceramic hearth plate 0 0 will be displayed NOTE DO NOT procedure to step 11 until display reads 0 0 11 Press the balance ENTER key BUSY will be displayed 12 The balance display will...

Page 35: ...ng the calibration procedure If this error is only displayed when calibrating the unit the software is bad and the unit needs to replaced 4 4 RS232 buffer is full There is a bad Double check all conne...

Page 36: ...tion Replace scale load not within 1 of cal weight or weight unstable PPPPPP Strain on the DC power supply Disconnect printer to see if the error goes away If it does replace printer ProtEc Calibratio...

Page 37: ...ket on an 8 5 x 11 piece of white paper Do not store the thermal paper ticket itself as it will discolor and become illegible in time RS232 Connection Information The 1087 and 1275 series NCATS are eq...

Page 38: ...degree symbol on the front display would not print with the Martel SOFTWARE UPDATE REV H software was only used in production for a couple of months Behind the scene changes were made and we are now u...

Page 39: ...ch is removed in software on off key located below the place of a jumper wire Wire green power switch on the front control harness part number WH1087X2 panel If this switch SWX108 is in the connects t...

Page 40: ...hidden key two routine when versa powering back on Test printer again If still printing upside down or right to left replace the printer Printer ticket indicating If the time and date are not set The...

Page 41: ...ing new software use part number AY1087X3 The latest version in production will be shipped Barnstead will not provide software versions used in the past Only the latest revision is production Versions...

Page 42: ...ours of operation the display will read In Ac in the chamber temp window This feature will benefit operators with NCATs in remote loca tions should the operator not be able to return to power off unit...

Page 43: ...ew months in early 2002 Version I Revision I is currently being used in production August 15 2002 and shipped as replacement software for NCAT units Revision I contains behind the scenes changes enabl...

Page 44: ...minutes and load size to 4 000 grams Meets ASTM and AASHTO maximum load size requirements Saves time no need to split sample size Asphalt content expressed in percent loss Meets ASTM and AASHTO test...

Page 45: ...into the open socket Adjust pins on a flat surface if not match ing socket 5 Refasten control panel 6 Turn power switch on Review and adjust default values 7 Your unit is now ready for operation 45 SO...

Page 46: ...RESET CRY1 R14 J3 SSR C26 C27 R19 R20 R21 R22 J2 LEDS C22 INTERCOM J4 R38 R37 R2 J32 C16 C15 C3 5DIG U4 C4 SCALE U7 R3 C20 R10 C9 U12 J7 J5 R25 J1 R23 R1 R24 R39 C2 U3 R5 R15 U9 C1 J9 DISPLAY 5DISP C6...

Page 47: ...47 Ordering Information Revision I Software Kit AY1087X3 1 ea SC859X1 EPROM Labeled Rev I Software 1 ea Installation Instructions 1 ea Set of Operation Manual Amendments SOFTWARE...

Page 48: ...mediately each day but only run your furnace as much as necessary to complete your days work Programming the Timer The following directions will explain how to program the wake up date and time into y...

Page 49: ...the unit be placed in a remote location and the operator is not able to return due to unexpected circumstances such as inclement weather The unit will remain shut down until the user presses the START...

Page 50: ...ntil 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 endpoint and place an asterisk by the endpoint It will contin...

Page 51: ...the 2 key while simultaneously depressing Power Switch to ON Procedure DEF will be displayed for three seconds to indicate variables have been reset to factory values The furnace will return to norma...

Page 52: ...calibration is required is 50 C Access Depress 3 key while simultaneously depressing power switch to ON Procedure CHBR CAL will be displayed in the Percent Loss and Elapsed Time windows respectively T...

Page 53: ...5 Key Filter Temperature Adjustment Access Depress 5 key while simultaneously depressing the Power Switch to ON Procedure Adjustment range is 0 900 C Factory set point is 750 C Chamber Temperature dis...

Page 54: ...multaneously depressing the Power Switch to ON Procedure Chamber temperature will display actual chamber temperature The Percent Loss displays actual filter temperature Use for diagnostic purposes onl...

Page 55: ...endpoint beeps to activate prematurely before the procedure has been completed The key press beep is not disabled in the BEEP OFF mode Weight Key Prints Out Balance Variables Access Depress the weigh...

Page 56: ...ure The stability threshold setting will be dis played in the Percent Loss window The Elapsed Time window will display FLN The value options are 0 01 0 02 0 03 0 04 Enter the new value via keypad Obse...

Page 57: ...ow in the Auto Program Switching to Idle mode Repeat Access again to return to the Manual Program Switching to Idle mode Auto Program Switching to Idle can increase the number of tests run per day The...

Page 58: ...he balance must be tared before conducting test See Glossary The weight of the loaded basket assem bly can be rechecked if the balance is tared prior to loading Exit Automatic Enter Key Duplicates Hea...

Page 59: ...nsation minus cor rection factor The Bitumen Ratio test results are printed in the header above the calibrated asphalt content for each test NOTE When developing aggregate calibration factors the desi...

Page 60: ...the ignition process This loss or gain is not related to asphalt con tent loss and is added or sub tracted from the asphalt content Standard methods specify the procedure for determination This calib...

Page 61: ...easures the blower efficiency when the furnace is in an unloaded condition and is at room temperature The operator is required to tare the balance depress the start stop key and observe the balance di...

Page 62: ...sample weight loss does not exceed the Test Stability Threshold Setting for three con secutive one minute periods Furnaces containing Rev I soft ware will end the test asterisk the endpoint reading on...

Page 63: ...leads labeled wrong red wire magnetic yellow wire non magnet ic or thermocouple connected to the wrong con nector i e Chamber thermocouple wiring con nected to the filter thermocouple wiring Same wit...

Page 64: ...has failed Moss FET on board has failed Turn the unit off and power back up If E003 comes up then proceed with E003 information above If E003 does not come up then replace the Logic PC Board or the M...

Page 65: ...eep for 3 seconds while dis playing this error and then return to normal operation The setpoint will revert to its previ ous valve Chamber temperature is to be less than 674 C Filter temperature is to...

Page 66: ...rect weights Make sure all debris is off the top of the balance and the posts supporting the aluminum calibration plate are centered Only the aluminum calibration plate should be used during the calib...

Page 67: ...sition during opera tion System not calibrated Internal arithmetic overflow Processor stack overflow Memory indexing error Unable to process command usu ally due to being in improper mode Solution con...

Page 68: ...e Section for proper lift test procedure Action Test keypad See Equipment Test Procedure section Replace keypad Serial number of NCAT need ed to identify correct replacement part number of keypad Test...

Page 69: ...nt air into the control section from the room It should not be pulling air out of the NCAT control section Axial fan may need to be remounted properly or replaced Test the afterburner element in the 1...

Page 70: ...ght loss at the 15th minute If not greater than 15 grams unit is performing as it should See Sample Ticket Section Perform a hidden key 2 routine and attempt to burn a 1500 gram sample Initial sample...

Page 71: ...ce balance Verify chamber temperature accuracy recali brate if necessary REMINDER Barnstead International has premixed samples of asphalt that can be sent to customers that have problems burning obtai...

Page 72: ...nsive test ing with Dolomite based samples Copies of results are available upon request Hydrated Lime is sometimes added to to HMA to improve binder adhesion to certain aggregates Hydrated lime will m...

Page 73: ...e in the buildings ventila tion system not the fault of the NCAT There are a cou ple of options if the NCAT is to be installed at this loca tion 1 Open any doors or windows in the room This may be eno...

Page 74: ...emp window to indicate the variables have been set back to factory default Variables affected are chamber temperature 538C filter temperature 750C and stability threshold 02 Hidden Key 2 reset vari ab...

Page 75: ...l cause SCAL to be displayed FLN Stability Threshold FLN will be displayed in the Elapsed Time window Hidden Key CALIBRATION FAC TOR will cause FLN to be displayed AU Auto Program AU will be displayed...

Page 76: ...4 34 7 3 45 10 512 26 9 2 46 9 511 14 1 1 29 8 492 10 3 0 32 Example of an Ohaus balance configured incorrectly 7 481 0 0 0 0 0 0 weight loss during the first 1 7 minutes 0 00 6 477 0 0 0 0 for the te...

Page 77: ...An example of the time date function of the balance not 17 544 0 6 0 02 properly set The decimal place is actually moved 4 digits 16 544 0 6 0 02 to the left 15 543 0 6 0 02 14 542 0 6 0 02 13 540 0...

Page 78: ...00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 An I C chip on the main PC board was not properly placed 0 00 in the socket causing the print out to look like this 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00...

Page 79: ...96 14 542 0 05 0 01 13 540 39 7 3 72 12 536 175 1 11 4 11 534 12 1 2 44 10 512 26 9 2 46 9 511 14 1 1 29 8 492 10 3 0 32 Balance plate is catching or the support columns holding 7 481 102 5 3 31 the...

Page 80: ...1 4 40 17 544 25 7 4 27 16 544 14 2 3 89 15 543 10 3 3 32 The sample did not lose 15 grams in the first 15 minutes 14 542 9 9 2 21 This particular sample will run non stop as a result 13 540 9 2 2 01...

Page 81: ...s ing The control assembly if properly disconnected can be slid out of the back of the unit To disconnect the control panel 1 Remove the eight screws along the lower out side back wall secure the cont...

Page 82: ...all eight screws are removed from the back of the control assembly you can slide the control assembly out of the back of the unit Notice the assembly will only slide back for about an inch Then it wil...

Page 83: ...bon cable from the printer b 2 red wires and two black wires running from the green power switch that needs to be discon nected from the lower right hand corner of a sil ver box red wires go towards t...

Page 84: ...ay ribbon connector labeled P3 There is a special end on this harness that dis tinguishes it from the others The L shaped red display board only has two wire harnesses that need to be removed h A gray...

Page 85: ...e harness consists of 3 white wires and one green yellow wire Push the tabs on the sides and gently lift the connector up to disconnect b The second wire harness in back consists of 4 white wires for...

Page 86: ...ouple wires Red and Yellow will come into view and prevent the control sec tion from sliding any further The thermocouple connectors are green the connectors also have a C for chamber and F for filter...

Page 87: ...ack into the unit The biggest cause of failure when reinstalling the control section is having wire harnesses that are not plugged in properly TIP Do not ever tug on wires in an attempt to disconnect...

Page 88: ...break the thermocouple back of unit 6 Remove the chamber thermocouple lower ther mocouple TC859X1A taking care not to phys ically break the thermocouple back of unit 7 Loosen the screws that secure th...

Page 89: ...chamber from the front EL1087X2 22 Remove the back wall ceramic piece PH412X1 23 Remove the back wall insulation piece JC1087X3 Install the replacement JC1087X3 position into place By following the pr...

Page 90: ...terburner element in the 1087 or 1275 series NCAT can not be tested in this manner because the sur face area of the element is embedded in the top plenum of the chamber B Heating Elements ohm check pe...

Page 91: ...can remain in the unit 8 Measure the resistance between the element lead wires on each element with an ohmmeter Refer to chart on page 95 to obtain element cold resistance value 9 If the cold resista...

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Page 94: ...ks B Element terminal blocks C Element terminal blocks D Element terminal blocks E Element terminal blocks F Element terminal blocks G Element terminal blocks H Filter thermocoupler I Chamber thermoco...

Page 95: ...ies 859 945 Part Number Description Voltage Cold Resistance EL859X1 Top 220 240V 36 Ohms EL859X2 Bottom 220 240V 55 Ohms EL859X3 Right Side 220 240V 55 Ohms EL859X4 Left Side 220 240V 55 Ohms EL859X5...

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Page 98: ...he chamber and filter thermocouples every 12 months A Chamber Thermocouple Equipment needed Digital ohm meter or continuity tester Phillips screw driver 1 Disconnect the NCAT from the power source 2 T...

Page 99: ...1 The filter thermocouple is tested in the same man ner as the chamber thermocouple a The filter thermocouple is connected to the same terminal block located near the middle bottom of the back of the...

Page 100: ...esist ance or no continuity Do not attempt to connect a voltmeter in parallel with either thermocouple attempting to monitor the millivolt generated signal A meter will load the circuit resulting in i...

Page 101: ...wer motor exhaust fan A Solid State Relay Equipment needed Digital voltmeter DMM Phillips screw driver 1 Disconnect the NCAT unit from the power source 2 Remove the eight screws from the back of the c...

Page 102: ...green wire to pin 4 b The relay in the middle is for the chamber elements This relay will have two white wires connected to pins 1 and 2 a red wire to pin 3 and a black wire to pin 4 c The relay on th...

Page 103: ...ins 3 and 4 have a 5 to 15Vdc signal applied across them and at the same time no AC voltage can be measured across pins 1 and 2 b A solid state relay is also considered good if the input of relay pins...

Page 104: ...CAT unit from the power source 2 Lower the control panel by removing the 4 screws along the top edge Control panel hinges down ward 3 Locate and disconnect keypad from J2 terminal of display board 4 R...

Page 105: ...rix chart 105 EQUIPMENT TEST PROCEDURE 7 Key 8 Key 9 Key Temp Key 4 Key 5 Key 6 Key Weight Key 1 Key 2 Key 3 Key Cal Key Timer Key 0 Key Start Stop Enter Key Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7...

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Page 110: ...up 3 Press the 0 key on the keypad a This zeros the balance 4 Press the start stop key on the keypad a This initiates the blower motor 5 The green display will indicate a number approximately 20 seco...

Page 111: ...loose and the cham ber is sucking in air If there is no black streaks then continue to step 4 Tighten the door by opening it at a 90 degree angle in reference to the front of the chamber Loosen the do...

Page 112: ...t the chamber tem perature to your desired burning level Reset the filter temperature to 750 C by performing the hidden key 5 routine Routine cleaning of the NCAT is complete Chamber Temperature Verif...

Page 113: ...in the TEST mode will produce inaccurate results primarily because the exhaust fan is activated in the TEST mode pulling ambient air approximately 10CFM through the chamber Chamber Temperature Calibr...

Page 114: ...ndows The Hidden Key 3 routine will allow you to key in the chamber tem perature as measured by the pyrometer and recorded in step 7 10 Enter the new chamber temperature value recorded in step 7 follo...

Page 115: ...hole is predrilled through the stainless steel sheet metal but is not predrilled through the chamber insulation material A 1 4 diameter hole must be drilled through the insulation material to access t...

Page 116: ...eet cover Blanket Insulation Side element 240 V Insulation material Harder material Course Filter Afterburner Element Insulators Side wall insulation Side wall insulation Top element 240V Insulators B...

Page 117: ...lead wires Chamber T C Filter T C Element lead wires are pinched between the terminal block and a small flap of metal To loosen lead wires loosen screws and nuts that hold the metal flap against the...

Page 118: ...k of unit Nuts Washer Bracket Top Cover CV1087X15 Top Cover CV1087X13 Blower Motor Harness to disconnect blower motor Screws Metal cover Back cover chamber section Temperature probe port DRAWINGS REF...

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