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68

E

RRORS

NCAT Troubleshooting with No Error Codes Displayed

Error

Keypad failure

Blower motor failure

Low lift-test reading
(Complaint)

Symptom

The NCAT unit may beep or chirp
in a non-rhythmic fashion.

The red displays will indicate char-
acters (numbers and/or letters)
that do not coincide with what
should be displayed or what is nor-
mal.

NCAT performs a hidden key rou-
tine when initially powered on, yet
end user did not initiate a hidden
key routine.

Results from lift test will not meet
specifications.

Full potential line voltage is applied
to the blower motor in test mode
but blower will not run.

Motor may run, but makes abnor-
mal noises.

A low lift-test reading is when per-
formed by operators to signify rou-
tine maintenance needs to be per-
formed. Lift-test readings should
range from -3.0 to -8.2. (See
Maintenance 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 blower motor by monitoring feed voltage.

Voltage will measure full potential line voltage
on 945 series and 1087 series NCATs. 859
series units will measure full potential line volt-
age (if upgraded) or 120Vac.

Oil blower motor (See Maintenance Section.)

Replace blower motor. (Serial number of NCAT
needed to identify correct replacement part
number of blower motor.)

Follow the cleaning procedure steps. (See
Maintenance Section)

Test/replace the blower motor. (Serial number of
NCAT needed to identify correct replacement
part number of blower motor.)

The insulation in the upper plenum may need to
be replaced. If the blanket insulation is not tight-
ly tucked against the top sides of the NCAT, air
will not be forced through the five air baffle
holes. Instead the air escapes around the outer
edges resulting in a low lift test.

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Содержание Thermolyne 859 Series

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

Страница 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...

Страница 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...

Страница 4: ...4...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 11: ...11 INSTALLATION...

Страница 12: ...12 INSTALLATION...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 92: ...92...

Страница 93: ...93...

Страница 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...

Страница 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...

Страница 96: ...96...

Страница 97: ...97...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 106: ...106...

Страница 107: ...107...

Страница 108: ...108...

Страница 109: ...109...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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