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VERDER CARBOLITE GERO ABA 7/35B, Installation, Operation And Maintenance Instructions, Page: 29 / 94

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VERDER CARBOLITE GERO ABA 7/35B Installation, Operation And Maintenance Instructions Download Page 29

5.4

Operator Safety

The ABA incorporates a safety switch which interrupts the heating
element circuit when the door is opened. This prevents the operator
from touching a live heating element, but also prevents heating up if the
door is left open.

When a test is started the door is automatically locked until a constant weight loss (end-
point) is achieved. This is to prevent the operator from opening the door whilst volatiles
are being driven off from the test sample. If the door were to be opened during this
time the addition of air could cause the volatile materials to ignite in an explosive
manner.

The red sample basket cover must be used to cover the hot sample
baskets whilst they are allowed to cool.

Before removing any hot objects from the chamber make sure that you
have a safe place to put them down.

Do not place hot objects on inflammable surfaces. Wear appropriate
safety clothing; gloves, mask and safety glasses are recommended.

5.5

Touch-screen Main Menu

The main menu is accessed directly from the button in the top left corner of the home
screen as shown in Fig 36.

The table below gives a reference to a section of this document where detailed
information is given for each of the buttons on the Main Menu.

Fig 36 - Screen-view: Main Menu

29

5.0   ABA Operation

Summary of Contents for CARBOLITE GERO ABA 7/35B

Page 1: ...Installation Operation and Maintenance Instructions 750 C Asphalt Binder Analyser ABA Model 35 Litres ABA 7 35B MEN ABA735B 01 17 10 2018 ...

Page 2: ...and Setting Up 14 3 3 Tools Required 15 3 4 Fitting the Chimney 16 3 5 Ducting 16 3 6 Hot Sample Guard Assembly 17 3 7 Electrical Connections 17 3 8 Balance Installation 20 3 9 Installing Printer Paper 23 3 10 Calibrating Internal Balance 23 3 11 Connecting External Balance 24 4 0 Safety Features 25 4 1 Electric Shock Risk Lamps 25 4 2 Power Failure Safety Feature 25 4 3 Access to the Plenum Chamb...

Page 3: ...xplorer External Balance 37 7 10 1 Table Ohaus Balance Settings 38 7 11 Connecting an Ohaus Explorer Pro External Balance 38 7 12 External Balance Configuration 39 7 13 Entering Weights 39 7 14 Weight Entry Error Checking 41 8 0 Tray Lift Calculation 42 8 1 Lift Correction 42 9 0 Access Levels 44 9 1 Setting Operator and Supervisor Access Levels 44 9 1 1 Table Access Level Settings for Buttons def...

Page 4: ...er 60 15 1 Test Log File 60 16 0 USB Memory Stick Data Transfer 62 16 1 File Types and Copy Direction 62 16 1 1 Table USB Files 62 16 2 Screen Layout 63 16 2 1 Table LED Colours 63 17 0 Internal Balance Commands 64 17 1 Balance Command Screen 64 17 2 Tare Command 64 17 3 Calibrate 65 17 4 Filter Setting 66 18 0 Language Selection 66 19 0 Reconfigure Voltage Settings For Alternative Electrical Supp...

Page 5: ...ment Replacement 78 22 7 Door Plug Replacement 78 22 8 Catch Tray Straightening 78 22 9 Consumables 79 23 0 ABA 7 35B Interface Layout 80 24 0 Event Log Messages 81 25 0 Software Versions 83 25 1 Software Applications 83 26 0 Diagnostics 84 26 1 Diagnostic Screen 84 27 0 Fault Finding 85 A The Furnace Main Chamber or After burner Does Not Heat 85 B The Main Chamber or After burner is Slow to Heat ...

Page 6: ...30 0 Specifications 92 30 1 Representations Covered by this Manual 92 30 2 Updates 92 30 3 Environment 92 6 ...

Page 7: ...d to check the operation of the two red warning lamps situated above the main chamber on the right hand side of the ABA Heat light the adjacent light glows or flashes to indicate that power is being supplied to the elements Afterburner Heater Light the adjacent light glows to indicate that power is being supplied to the afterburner 1 2 General Warnings DANGER Electric shock Read any warning printe...

Page 8: ...s and Warnings DANGER Hot surface Read any warning printed next to this symbol WARNING All surfaces of a product may be hot DANGER Read any warning printed next to this symbol Caution Double Pole Neutral Fusing 8 ...

Page 9: ... 3 2039 set of 2 See Fig 2 2 Sample Basket Lids See Fig 2 2 Sample of Sample Basket Clips 1 large 1 small per set part number 35 090 044 0010 2 Sample Catch Trays part number 00336 3 2038 1 Sample Basket Loading Handle part number 00336 3 2041 See Fig 3 1 Hot Sample Safety Guard part number 00336 3 2042 including handles fixing kit See Fig 4 1 Hot Sample Guard Handle Fixing Kit See Figs 5 Fig 6 2 ...

Page 10: ...2 0 Supplied Item List In addition any spare parts ordered should be separately identified and put aside in safe storage 10 ...

Page 11: ...2 2 Identifying the Parts 11 2 0 Supplied Item List ...

Page 12: ...tension Fig 2 Sample baskets on catch tray with lids and clips Fig 3 Sample basket loading handle Fig 4 Hot sample safety guards assembled Fig 5 Hot sample safety guard handle fixing kit Fig 6 Safety warning label for hot sample safety guard 12 ...

Page 13: ...Fig 7 Front brick cover Fig 8 Calibration Plate Fig 9 Functional parts of the ABA 13 2 0 Supplied Item List ...

Page 14: ...is located on the right hand side of the case Lock the door again after checking and clearing the interior See section 4 2 NOTE This product contains Refractory Ceramic Fibre also known as Alumino Silicate Wool ASW For precautions and advice on handling this material see section 22 2 3 2 Siting and Setting Up Place the product on a level surface in a well ventilated area Site away from other sourc...

Page 15: ...can be quickly switched off or disconnected from the electrical supply Under no circumstances should any objects be placed on top of the product Always ensure that any vents on the top of the product are clear of any obstruction Always ensure all cooling vents and cooling fans if fitted are clear of any obstruction 3 3 Tools Required l 10 mm spanner l 12 mm spanner l Cross point screwdriver l Flat...

Page 16: ... duct must NOT have powered extraction The fumes should be ducted by either of the above methods to at least 1 metre above the level of the building Rules for ducting l Ducting diameter must be 76 mm or more l Ducting must be 76 mm where it connects to the chimney l Ducting length must not exceed 3 metre for 76 mm diameter for longer lengths con sult a ducting engineer l Flexible ducting if used m...

Page 17: ...ian is recommended Model ABA 7 35B is designed for connection to a range of power supplies with the minimum of circuit modifications It is initially supplied to suit the voltage for which it was ordered Look at the rating label before connection to check the electrical supply voltage and frequency for which the unit is configured If there is a difference between the actual supply and the rating la...

Page 18: ...standard size equal to or higher than the rated current A table of fuse ratings is given in section 29 0 Either wire directly to an isolator or fit with a line plug An isolating switch should operate on both conductors single phase or on all live conductors three phase it should be within reach of the operator A line plus should be easily removable and should b within reach of the operator The ele...

Page 19: ...Fig 14 Schematic for Mains Electrical Connections 19 3 0 Installation ...

Page 20: ...ning the plug s retaining screws then connect the balance s earth cable to the spade connector in the upper rear part of the recess see Fig 19 and Fig 20 Open the door lock with the key provided Insert the balance pan extension into the main chamber with the extension legs fitting through the four holes in the chamber hearth Fig 24 to Fig 25 Note that the front edge of the extension is folded down...

Page 21: ...o the balance Fig 19 Balance the earth cable position Fig 20 Close up of balance earth cable attachment Fig 21 Insert the balance through the left side with the read of the balance towards the front of the furnace Fig 22 Use sample tray and spirit level to level the balance Fig 23 Using a spanner adjust the legs on the balance until the indicator on the bubble arm shows that it is level 21 3 0 Ins...

Page 22: ...0 Installation Fig 24 Inserting the balance pan Fig 25 Balance pan extension in place Fig 26 Fastening the balance pan Fig 27 Allen key and screws Fig 28 Checking that the balance pan legs are central 22 ...

Page 23: ...pins to release the roll and its retaining disc Replace the printer roll using the paper path shown in Fig 31 Insert the straight edge of the paper into the slot at the bottom of the front panel and press the paper feed button at the same time which will draw the paper through the printer Close the printer to continue Fig 29 Release clip and swing open the printer Fig 30 Squeeze the spindle pins t...

Page 24: ...entering sample weights the ABA 7 35B can directly import sample weight values from certain external balances These include Ohaus Explorer models pre 2011 with monochrome LCD display and post 2011 with colour interface as well as Adam Equipment Balances see section 7 9 for connection details 24 ...

Page 25: ...for regular checking using the test switch 4 2 Power Failure Safety Feature A power failure could occur during a test leaving an incompletely burnt sample and a chamber containing explosive or volatile matter An interruption of power is normally signaled by the display of the Carbolite Gero logo on the balance display screen On a power failure the door remains locked and automatically opens only o...

Page 26: ...uminated in orange otherwise it is grey The user should always check that the door locked lamp is lit when a test is started 4 5 Maintenance or Dismantling NOTE This product contains Refractory Ceramic Fibre better described as Alumino Silicate Wool for precautions and advice in handling this material see the Safety Warning Refractory Fibre Insulation The user should disconnect the equipment from ...

Page 27: ...ys are on they flash while the chamber is heating or maintaining temperature They are also used to diagnose faults see section 27 0 5 2 Door Operation and Status Display In previous models door open and door locked indicator lamps were positioned above the Electric shock risk lamps on the upper right front of the furnace These door status indicators are now included see Fig 32 and Fig 36 in the st...

Page 28: ...tone will be emitted along with a warning screen indicating that The door should be closed and locked immediately This warning should not be ignored failure to do so may result in serious injury The test will continue when the door is once again locked Door Lock will operate under the following conditions l when the ABA is disconnected from the power supply the door is locked l when the illuminate...

Page 29: ...ould cause the volatile materials to ignite in an explosive manner The red sample basket cover must be used to cover the hot sample baskets whilst they are allowed to cool Before removing any hot objects from the chamber make sure that you have a safe place to put them down Do not place hot objects on inflammable surfaces Wear appropriate safety clothing gloves mask and safety glasses are recommen...

Page 30: ...e Section Temperature 10 System Configuration 6 factory settings Balance Menu 17 USB Data Transfer 16 View Test Results 15 Select Access Level 9 View Recipe Library 13 New Standard Recipe 14 New Calibration Recipe 14 Calculate Tray Lift 8 Software Versions 23 Hours of Use 0 30 ...

Page 31: ...this document where detailed information is given for each of the buttons on the Configuration Menu Fig 37 Screen view System Configuration Menu 6 1 1 Table System Configuration Menu References System Configuration Menu Button Reference Section General Settings 7 12 10 2 Set Date Time 11 0 Print Settings 12 0 Diagnostics 26 0 PID 1 Settings Factory Set PID 2 Settings Factory Set Voltage Settings 1...

Page 32: ...e in the recipe name field the temperature setpoint from the recipe and depending on the recipe type either the calibration factor or binder from the recipe will be displayed as shown in Fig 36 The furnace will heat the main chamber to the temperature specified in the recipe setpoint If the furnace has just been switched on from cold it should be allowed to dwell at the setpoint temperature for 30...

Page 33: ...ed off A recipe has been selected Select recipe from library Furnace door is closed Test not started due to open door Sample weight zero Enter Weights Tray weight zero Enter Weights Temperature setpoint is at the required test temperature Recipe temperature setpoint is zero Standard recipe calibration factor is zero Recipe Calibration Factor is zero Door lock operates Door has failed to lock 7 4 D...

Page 34: ...will be updated after 13 minutes and then every 30 seconds until the end of the test These values indicate the weight loss during previous x minutes where x is the constant weight time If the recipe type is calibration the calibration factor circled in yellow will be updated on test completion and if the recipe type is standard then the binder circled in blue will be updated on test completion If ...

Page 35: ...iscarded If the sample temperature within the chamber is under 120 C or if there is no sample present in the chamber then it is permissible to immediately cancel the test using the procedure given in section 7 7 Fig 41 Screen view Power Interrupt During Test Warning 7 6 End of Test Trigger The end of the test is determined by the three recipe parameters see Fig 42 The system can be set to use eith...

Page 36: ... Cancel Test button shown in the In Test Display screen see Fig 38 A pass number must then be entered The pass number should be communicated only to authorised operators this is a safety feature because of the danger of opening the door part way through a test the operator should know the danger others may not The password is fixed at 728 It is safe to cancel a test by this method if there is no s...

Page 37: ... pins are unused The external balance type must be set to Adam Equipment in the General Settings screen see Fig 45 The balance settings are shown below Baud Rate 9600 Parity None Stop Bits 1 Number of Bits 8 Refer to the Adam Equipment balance user manual for instructions on setting these parameters 7 10 Connecting an Ohaus Explorer External Balance This section refers to the Ohaus Explorer balanc...

Page 38: ...ternal Off Numeric Data Off Units Gram g On Baud Rate 9600 Parity None Data Bits 8 Stop Bits 1 7 11 Connecting an Ohaus Explorer Pro External Balance This section refers to the Ohaus balance with a colour touch screen interface The external balance type must be set to Ohaus Explorer in the General Settings screen see Fig 45 A standard straight through RS232 cable is used to connect the balance to ...

Page 39: ...t place the item to be weighed on the external balance and press either Get Tray Weight Get Combined Weight or Get Sample Weight as appropriate The relevant weight will appear opposite the button To manually enter weights press the white box for the required weight and the number pad will be displayed as shown in Fig 46 Note the top of the number pad indicates the item requiring a weight with the ...

Page 40: ...7 0 Running a Test Fig 46 Screen view Weight Entry Number Pad Fig 47 Screen view Successful Weight Entry 40 ...

Page 41: ...checking in the weight entry processing for both manual and automatic entry methods If the combined weight entered is less than or equal to the tray weight then the error message shown in Fig 48 pops up Fig 48 Screen view Weight Entry Error Message 41 7 0 Running a Test ...

Page 42: ...8 0 Tray Lift Calculation 8 0 Tray Lift Calculation 8 1 Lift Correction Fig 49 Screen view Tray Lift Correction In Progress Fig 50 Screen view Tray Lift Correction Complete 42 ...

Page 43: ...n is attempted an error message pops up When the Calculate Fan Lift button is pressed the ABA automatically performs the following sequence 1 Stop the extractor fan 2 Tare the balance 3 Start the extractor fan 4 Wait for the system to stabilize 5 Take a weight measurement and store the result in flash memory 6 Stop the fan 7 Indicate the calculation is complete 8 Write a message to the Event Log A...

Page 44: ...reen see Fig 51 Access Control Screen is accessed via Home Screen Main Menu Select Access Level The default pass code number for Supervisor Level 2222 see Fig 52 Supervisor and Operator access is controlled using a system configuration file which is held in the flash memory on the controller Changes to this file can be requested and a new copy uploaded to the system from a USB memory stick The def...

Page 45: ...upervisor Pass Code Entry 9 1 1 Table Access Level Settings for Buttons default factory settings Button Name Supervisor Access Operator Access After Burner Setpoint N N Balance Menu Y N Calculate Tray Lift Y N Calibrate Y N Cancel Test Y N 45 9 0 Access Levels ...

Page 46: ... General Settings Y N Language Settings Y Y Load Access File Y Y Load Passwords Y Y Load Recipes Y N Load Settings N N Main Chamber Setpoint Y Y Main Menu Y Y New Calibration Recipe Y N New Standard Recipe Y N PID Settings N N Print Settings Y N Recipe Copy Y N Recipe Delete Y N Recipe Edit Y N Recipe Run Y Y Reset Hours of Use N N Run Test Y Y Save Recipe Y N Set Date Time Y N System Configuratio...

Page 47: ...upervisor Access Operator Access View Recipe Library Y Y Voltage Settings N N If a button is not listed in the above table then it is accessible at all levels e g the Select Access Level button 47 9 0 Access Levels ...

Page 48: ...en then the LED colour is red as shown for the after burner in Fig 53 If the connection is good the LED is coloured green The Main Chamber setpoint can be changed by pressing the white box which will cause a number pad to pop up The After Burner setpoint is factory configured to be 900 C If a recipe is selected see section 7 2 then the Main Chamber temperature set in the recipe will show on this s...

Page 49: ...status of the heater power is determined by an Initial Heater Setting which is located on the General Settings screen see Fig 54 General Settings Screen is accessed via Home Screen Main Menu System Configuration General Settings The factory default for this setting is off This ensures the furnace will not heat up after applying power for the first time during installation and hence protects any it...

Page 50: ... Screen The date and time setting screen see Fig 55 is accessed via Home Screen Main Menu System Configuration Set Date Time To change a date or time element press the relevant white box This will open the number pad screen see Fig 56 and the relevant number can be adjusted accordingly 50 ...

Page 51: ...Fig 55 Screen view Date and Time Setting Screen Fig 56 Screen view Date Time Number Pad 51 11 0 Setting the Date and Time ...

Page 52: ... display This is useful because the printer does not currently support Cyrillic and Kanji fonts Note if the screen language is set to English and the printer is set to Current selected language then printouts will be in English The Print Period setting controls the time interval between printouts during a test and can be configured to be from 30 to 300 seconds If a recipe Print Format is configure...

Page 53: ...Fig 57 Screen view Printer Setting Screen Fig 58 Screen view Recipe Setting for Print Output 53 12 0 Printer Settings ...

Page 54: ...ipe name This will cause it to be highlighted in dark blue as shown for RCP1 in Fig 59 Note A recipe name preceded with the tilde character is a calibration type recipe Recipe type is determined at the point of creation and cannot be changed later Fig 59 Screen view Recipe Library 13 2 Copy Recipe To copy a recipe first select it by touching on the name then press the copy button and this will cau...

Page 55: ...me and then press the Delete button shown in Fig 59 A confirmation dialog box will be displayed Press OK to continue deleting or Cancel to stop the operation 13 5 Run Recipe To run a test with a recipe first select it by touching on the name and then press the Run button shown in Fig 59 The controller will display the Home screen populated with the values from the selected recipe ready for the ope...

Page 56: ...recipe has a Binder Content parameter see Fig 62 The Calibration recipe is run with a sample where the binder content is known This is zero for an aggregate only test The final test result will give the calibration factor This factor can then be used in standard recipes The standard recipe editor see Fig 61 is accessed via Home Screen Main Menu New Standard Recipe The calibration recipe editor see...

Page 57: ...Fig 61 Screen view Standard Recipe Fig 62 Calibration Recipe 57 14 0 Recipe Editor ...

Page 58: ...e Min Weight Change Constant Mass Limit and Constant Weight Time are described in section 7 6 14 5 Initial Delay Time The Initial Delay Time parameter is the time period in minutes from the start of the test to the point where the End of Test conditions are monitored This prevents a false End of Test condition from being detected at the start of the test When testing an aggregate to determine an a...

Page 59: ...ses the following ASTM equation Binder M1 M2 M1 x 100 Calibration Factor Where M1 total mass of sample prior to ignition M2 total mass of aggregate remaining after ignition 14 9 Calibration Factor Applicable only to standard recipes This value is obtained by operating a calibration recipe with a know sample 14 10 Binder Content Applicable only to calibration recipes This is the percentage binder c...

Page 60: ...d The log files can also be copied to a USB memory stick as described in USB Memory Stick Data Transfer and viewed on a PC using a text editor such as Notepad To open a log file first select a file by touching the one required in the list then press Open File The file contents are then displayed as shown in Fig 65 with the file name circled in green The tests are displayed in chronological order w...

Page 61: ...Fig 64 Screen view Test Log Viewer File List Fig 65 Screen view Test Log Viewer File Contents 61 15 0 Test Log Viewer ...

Page 62: ...ration files across multiple systems It allows test results and event information to be stored and viewed on a PC It provides a method for adding or updating new local languages The file details are listed in the table below 16 1 1 Table USB Files File Description Reference Test Log File Contains test results Test Log Viewer Event Log File Contains significant event information and time stamp e g ...

Page 63: ... be seen in Fig 66 The colours of the LEDs on the USB Data Transfer screen for different actions are shown in table below 16 2 1 Table LED Colours LEDs and Colour Memory Stick Inserted File Transfer in Progress Memory Stick Detected Copy Files Safe to Remove Memory Stick No N A Grey Grey Grey Yes No Green Grey Green Yes Yes Green Red Red Fig 66 USB Data Transfer Test Event Log Tab 63 16 0 USB Memo...

Page 64: ...splay Ready If communication is lost between the balance and the controller the balance status will display No reply to set up command and the cable between the controller and balance should be checked Fig 67 Screen view Balance Control Screen Idle 17 2 Tare Command Pressing the tare button will zero the balance by sending a tare command to the balance The balance status will display Tare started ...

Page 65: ...then press Next l Load 5 kg then press Next l Calibration Complete After pressing the calibration button the Next and Cancel buttons appear Cancel can be pressed at any time to abort the operation These buttons can be seen in Fig 68 NOTE When loading 5 kg the weight reading will remain at zero this is normal After the calibration is complete the balance weight will read 5000 g until the weight is ...

Page 66: ... The screen can display text in different languages provided the relevant language translation files have been loaded onto the controller Also the test results see section 15 0 will be stored in the selected language The language selection screen is accessed via Home Screen Main Menu System Configuration Language Setting The screen is shown in Fig 69 with English selected To change a language pres...

Page 67: ...the time of order no adjustment is necessary Adjustment is required if the equipment is relocated to a different voltage power supply Adjustment of the power limit should not be made arbitrarily for example to increase the power the heating elements could burn out or heating could become slow The voltage setting screen Fig 70 is accessed via Home Screen Main Menu System Configuration Voltage Setti...

Page 68: ...bration In the Temperature Point box enter the temperature at which you want to apply your offset In the Offset box enter the offset value This offset will be applied across the respective temperature range The Calibrated Temperature box then will display the result of the offset at the selected Temperature Point Select Validate and the temperature displays below the Validate button will show the ...

Page 69: ...erature Point In the High Temperature Point box enter the higher temperature at which you want to apply your offset In the Offset box enter the offset value for the high temperature point The Calibrated Temperature box will then display the result of the offset at the selected Temperature Point Select Validate and the temperature displays below the Validate button will show the Non Calibrated Temp...

Page 70: ...20 0 Temperature Calibration Fig 72 Screen view Dual Point Calibration 70 ...

Page 71: ...ched off ensure that the door is locked Safety Switch Function Electrical measurement Safety Circuit Test Switch Test the operation of the Electric Shock Warning Lights by operating the Safety Circuit Test Switch as described in this manual Door Plug Visual inspection checking the seal and whether it is free of damage Door Plug Replacement where necessary Door Seal Visual inspection check for spli...

Page 72: ... been fitted Operational Check Check that all functions are working normally Operational Check Thorough inspection and report incorporating a test of all functions Performance Element Circuit Electrical measurement Power Consumption Measure the current drawn on each phase cir cuit Balance Pan Extension Visually check to make sure the pan is level and undamaged With an empty chamber make sure the b...

Page 73: ...hich is shown on the screen during the start up sequence 21 4 Cleaning and Hours of Use Monitoring Soot can accumulate in the airway following the after burner giving rise to fire risk There is a plenum chamber with removable panels to give access to cleaning see section 21 5 The operator is responsible for maintaining a clean plenum chamber and also for regular cleaning of the chimney and the ext...

Page 74: ...plenum chamber see Fig 75 and Fig 76 Clean out all accumulated soot and debris using a vacuum cleaner Also clean any accumulated soot and debris from the fan impeller located at the back of the plenum chamber If the accumulation of soot on the impeller is significant it may be necessary to remove the motor impeller assembly from the back of the plenum chamber to give good access for cleaning 74 ...

Page 75: ...rts and Spare Parts Kit Carbolite Gero can supply individual spare parts or a kit of the items most likely to be required Ordering a kit in advance can save time in the event of a breakdown Please consult Carbolite Gero s Sales Department for details of recommended spare parts 75 21 0 Maintenance ...

Page 76: ... there is no evidence of any long term health hazards it is strongly recommended that safety precautions are taken whenever the materials are handled Exposure to fibre dust may cause respiratory disease When handling the material always use approved respiratory protection equipment RPE eg FFP3 eye protection gloves and long sleeved clothing Avoid breaking up waste material Dispose of waste in seal...

Page 77: ...roller wear an anti static wrist strap or otherwise avoid any possibility of damage to the unit by static electricity Refer to the detailed instructions supplied with the replacement controller 77 22 0 Repairs and Replacements ...

Page 78: ...e K green negative white Disconnect the thermocouple from its terminal block and withdraw the thermocouple from its sheath by bending the metal tag or releasing the screw to release It is also advisable to remove the sheath and shake out any broken pieces of thermocouple Re assemble with a new thermocouple observing the colour coding ensuring that the thermocouple is not twisted as it is being ins...

Page 79: ...ighten the tray by resting the two lower corners on supports and pressing down on the higher corners Repeat this operation until the tray is flat 22 9 Consumables Printer Paper standard till roll paper 2 57 mm wide Carbolite Gero part number 22 222 356 0010 Printer Ribbon Epson ERC 09 79 22 0 Repairs and Replacements ...

Page 80: ...23 0 ABA 7 35B Interface 23 0 ABA 7 35B Interface Layout 34 screens which are mapped out as shown below the settings do not represent default values 80 ...

Page 81: ...tem configuration was made Refer to section 16 0 for details on copying files to a USB memory stick The possible events that are written to the log file are l Power Up l Supervisor access level set l Operator access level set l Configuration access level code changed l Supervisor access level code changed l Tare balance command l Calibrate balance command l Cancel calibrate command l New weights e...

Page 82: ...8 10 46 23 Error communicating with I O Board Code 2 10 46 36 Error communicating with I O Board Code 3 10 46 50 Error communicating with I O Board Code 3 10 47 02 Error communicating with I O Board Code 3 10 47 46 Power up 10 48 21 Error initialising I O Board comms Code 11 10 48 23 PIC comms error 10 49 27 Power up 11 29 28 Configuration access level set 11 30 00 Overwriting existing recipe CARB...

Page 83: ...ents can be changed independently a software version number is reported for each one These version numbers can be found via Home Screen Main Menu Software Versions Fig 75 shows the software versions screen On entering this screen a request is sent to both the balance and the temperature board to send their version numbers If the balance is not connected then 000 00 will be displayed Fig 75 Screen ...

Page 84: ... is also a fault LED indicator which turns red if there is an internal problem with the temperature control PCB In the event of a fault a fault code number may be displayed to the right of this LED Under normal operation this LED should be green as seen in Fig 76 The door relay input indicates the state of the contacts within the door lock mechanism If the door is open these contacts are open This...

Page 85: ...ow temperature The door switch may be faulty A relay may be faulty The SSR could be failing to switch on due to internal failure faulty logic wiring from the controller or faulty controller The controller is not illuminated Check the supply fuses and any fuses in the control compartment The controller may be faulty or not receiving a supply due to a faulty switch or a wiring fault B The Main Chamb...

Page 86: ...e been moved out of the heating chamber The thermocouple may be connected the wrong way round The controller may be faulty The heat lamp s remain on when the controller is off The SSR has failed ON Check for an accidental wiring fault which could have overloaded the SSR A temperature that is higher than the setpoint is shown during the test No fault Burning bitumen causes the temperature to increa...

Page 87: ... have been turned off during a test or there may have been a power failure during a test Enter START PROCESS then cancel the test THE RELEASE CODE 728 is REQUIRED Failure of interface board Loose connection lead Check all leads Door does not lock at start of test The key has been used and left in unlocked position Set the manual override to the locked position Door switch failure Interface board f...

Page 88: ...free to move Check for obstructions such as aggregate in the balance pan extension holes Loose wires obstructing balance pan Check control compartment Unit not on firm base Reposition ABA or adjust stand Fan motor support bracket has failed Check adjust motor support bracket Fan failure causing vibration Check replace motor or impeller 88 ...

Page 89: ...connection lead Check all leads H Test Problems Early termination of test Test parameters of trigger weight set too high Adjust to suitable setting Test parameter of constant weight delay set too low or zero Adjust to correct setting and save delete any old setting Balance unstable See balance errors I Printer Problems Printer does not print Printer is out of paper Add more printer paper Faulty pr...

Page 90: ...28 0 Circuit Diagram 28 0 Circuit Diagram Note Full size wiring diagram can be supplied on request Drawing number 0036 3 5000 01 02 90 ...

Page 91: ... fuse rating should be as follows Model Phases Volts Supply Fuse Rating ABA 7 35 1 phase 200 V 240 V 40 A ABA 7 35 3 phase with neutral 380 220 V 415 240 V 16 A per phase ABA 7 35 3 phase delta 200 V 240 V 25 A per phase 29 2 Power Settings The ABA 7 35 uses electronic power limiting to enable the same heating elements to be used over the complete range of voltages from 200 V to 240 V It is import...

Page 92: ...12697 39 2004 and ASTM D6307 10 and AASHTO T308 10 Height without chimney 980 mm Heights with chimney 1160 mm Width 600 mm Depth length 770 mm Optional Stand 600 mm high Weight 120 kg approximate Power Rating 8000 Watts 30 2 Updates Serial Number Update 21 400274 onwards New door Lock key 30 3 Environment The equipment contains electrical parts and should be stored and used in indoor conditions as...

Page 93: ...Notes Service Record Engineer Name Date Record of Work ...

Page 94: ... us at the address below or ask your nearest stockist For preventive maintenance repair and calibration of all furnace and oven products please contact Carbolite Gero Service Telephone 44 0 1433 624242 Fax 44 0 1433 624243 Email ServiceUK carbolite gero com Carbolite Gero Ltd Parsons Lane Hope Hope Valley S33 6RB England Telephone 44 0 1433 620011 Fax 44 0 1433 621198 Email Info carbolite gero com...

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