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Contents
Preface 4Unpacking 4Warranty 4After-SaleSupport 4
Section1:Introduction 5Section2:Safety 6
2.1ForOwners,Operators,&Maintenance 62.2SafetyInstructions 72.3Warnings 72.4Cautions 8
Section3:SystemOverview 93.1GeneralDescription 93.2Specifications 103.3EnvironmentalConditions 11
Section4:UnpackingandInstallation 124.1Unpacking 124.2Installation 124.3PanHolderLeveling 124.4AirandPowerConnections 13
Section5:Operation 16
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Contents
Section6:Verification 436.1VerifyingTemperature 436.2VerifyingPressure 44
Section7:Troubleshooting 457.1TemperatureDoesNotRecovertoSetpoint 457.2TroubleshootingthePAVController 467.3ReattachingtheFlowAdjustValve 477.4UpdatingtheSoftware 49
Section8:Maintenance 518.1PreventiveMaintenance 518.2ChangingFuses 518.3SpareParts 52
AppendixA:Warranty 54
RevisedJanuary2015
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PrefaceUnpackingRetainallcartonsandpackingmaterialsuntiltheunitisoperatedandfoundtobeingoodcondition.Ifdamagehasoccurredduringshipping,notifyAppliedTestSystems(ATS)andthecarrierimmediately.Ifitisnecessarytofileadamageclaim,retainthepackingmaterialsforinspectionbythecarrier.
WarrantyAllnewATSsystemsareshippedwithawarranty.Unitshaveawarrantyagainstdefectivepartsandworkmanshipforonefullyearfromdateofshipment.PleaseseeAppendixA ofthismanualforcompletedetailsonthewarranty.
NOTE:Pleaseseethewarrantyinformationincludedwiththecomputer.ItdetailsinformationthatwillensurepropertransferofthecomputerwarrantyfromATStotheappropriatecompany.
After-Sale SupportIfthereareanyquestionsconcerningtheoperationoftheunitorsoftware,contacttheATSServiceDepartmentat+1-724-283-1212.Beforecalling,pleaseobtainthesoftwarerevisionnumberandtheserialnumberfromtheunit’sdatatag.Asampledatatagisshownbelowandcanbecompletedwiththeunit’sinformationforeasyreference.PleasebepreparedtogiveacompletedescriptionoftheproblemtoATSServiceEngineers.
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Section1:IntroductionTheAppliedTestSystems(ATS)PressureAgingVessel(PAV)simulatesin-serviceoxidativeagingofasphaltbinderaccordingtoproceduresdevelopedbytheStrategicHighwayResearchProgram(SHRP).ThePAVsystemisfullycompliantwiththemostrecentversionsofASTMstandardD6521andAASHTOstandardmethodR28.
Thisinformationisrelatedtothefunction,setup,safeoperation,andmaintenanceofthePAVanditsrelatedcomponents.
Thismanualisintendedforanyonewhowillbesettingupand/oroperatingthePAV.
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Section2:SafetyAllATSequipmentisdesignedtobeoperatedwiththehighestlevelofsafety.ThismanualandATSendeavortoeducatetheoperatoraboutsafetyissuessurroundingcertainpartsofthemachinerybyusingequipmentlabeling.
2.1 For Owners, Operators, and Maintenance PersonnelReadandunderstandallinstructionsandsafetyprecautionslistedinthismanualbeforeinstallingoroperatingtheunit.Ifthereareanyquestionsregardingoperationoftheunitortheinstructionsinthismanual,contacttheATSServiceDepartmentat+1-724-283-1212.
Inadditiontothesafetywarningslistedontheequipment,warningsarepostedthroughoutthismanual.Readandfollowtheseimportantinstructions.Failuretoobservetheseinstructionscanresultinpermanentdamagetotheunit,significantpropertydamage,personalinjury,ordeath.
ReadOperator’sManual
General Danger
ProtectiveEarth(Ground)
BurnHazard(HotSurface)
ElectricalShock/Electrocution
HandCrushForceFromAbove
EuropeanDirectiveCEMark
NoAccessforUnauthorizedPersons
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2.2 Safety Instructions1.Readandfollowallwarningandcautionstatementsinall relatedequipmentmanualsbeforeattemptingtooperate thismachine.Ifindoubtaboutanystatementorsequence,contactATSService.
2.Installationofelectricaldevicesmustbeaccomplishedby competentpersonnelanddoneinaccordancewithany currentlocalandnationalcodes.EquipmentgroundingisaMUSTforbothsafetyandproperoperation.
3.Beforesupplyingelectricalpowertotheunit,turnallpowerswitchesandcontrolstoanOFForNEUTRALposition.
2.3 WarningsThefollowingstatementsarewarningstatements.Unlikecautionstatements,warningstatementsalerttheoperatortoconditionsthatmayinjurepersonnel.Operatorsmustbeawareoftheseconditionsinordertopreventinjuriesthatmayoccurwhileoperatingthisequipment.
WARNING:Obeyelectricalcoderequirements.Theovenandcontrolsystemmustbewiredandgroundedinaccordancewithnationalandlocalelectricalcode
requirements.
WARNING:Becarefulwhenworkingwithequipmentatelevatedtemperatures.Inordertopreventburns,wearprotectiveclothing.
WARNING:Usecautionwhenopeningtheovenlid.Electrically-heatedequipmentcancausesevereburns.
WARNING:Allowadequatetimetorelieveallthepressurefromthevesselbeforeopeningtheovenlidandthepressurevessellid.Anyunrelievedpressurecan
causeequipmentdamageandpossiblepersonalinjury.
WARNING:Unpackandoperateonastablesurface.
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2.4 CautionsThefollowingstatementsarecautionstatements.Thesestatementsalerttheoperatortoconditionsthatmaydamageequipment.Operatorsmustbeawareoftheseconditionsinordertoensuresafeoperationofthisequipment.
CAUTION:Installationofelectricaldevicesmustbeaccomplishedbycompetentpersonnelanddoneinaccordancewithanycurrentlocalandnationalcodes.
CAUTION:ThePAVmustbegroundedandwiredinaccordancewithnationalandlocalelectricalcoderequirements.
CAUTION:BeforeenergizingtheelectricalpowertothePressureAgingVessel,placeallcontrolsinanOFFposition.
CAUTION:Donotexceedthemaximumoperatingtemperature.RefertothespecificationsinSection3ofthismanual.
CAUTION:ClosingtheflowadjustvalvewhenthePAVisinoperationwillcausedamagetothevalve.
CAUTION:Allsupportingandcontactingsurfacesmustbenon-flammable.Donotallowflammablematerialstocontacttheshell.
CAUTION:Ifanemergencyshutdownneedstobeperformed,placeON/OFFswitchinanOFFposition.Unitwilldepressurizeautomaticallywithin10-15minutes.
CAUTION:DonotoverflowPAVpans.Refertotestspecificationsforproperamountofmaterial.
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Section3:SystemOverview
3.1 General DescriptionTheATSPressureAgingVessel(PAV)isdesignedspecificallytopreparespecimensfortestsdevelopedbytheStrategicHighwayResearchProgram(SHRP)tosimulatein-serviceoxidativeagingthatoccursinasphaltbindersduringservice.
APAVsystemconsistsofthefollowing:ASME/CEcodestainlesssteelpressurevesselenclosedinastainlesssteeloven,pressureregulator,meteringvalve,pressuretransducerandindicator,RTD,temperaturecontrollerwithdatalogging,andpanholder.
3.1.1 Vessel Certification
ASMECode:Unlessotherwisenoted,thePressureAgingVessel(PAV)isdesigned,fabricated,inspected,tested,andstampedinaccordancewiththeASME Boiler and Pressure Code,SectionVIII,Divison1,forserviceatamaximumpressureof2.45MPa/350psigandamaximumtemperatureof150°C/300°F.The ASME Boiler and Pressure Vessel CodeisanInternationallyRecognizedStandard.
ContactATSforthevesselcertificate/U-IAReportandCEDeclarationofConformity.
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3.2 SpecificationsBenchtopUnit IntegralVessel/OvenDesign
VerticalLoadingwithFixture
SpecimenCapacity 10Pans
SpecimenPans PerAASHTOT179
PhysicalDimensions 30”high,18”deep,27½”wide (760mmhigh,460mmdeep,700mmwide)
Weight 290lbs(130kg)
OperatingPressure 304.5psi(2.1±0.05MPa)
TemperatureAccuracy Setpoint±0.5°C
TemperatureRange 80°Cto115°C
RTDTemperatureMeasurement 0.1°CResolutionand±0.1°Accuracy MicroprocessorTemperatureControl
OvertemperatureProtection
PowerRequirements
ASMEOvenHighLimitSwitch293°F(145°C)
240VAC,10amps,50/60Hz
VesselPerASMECodeSectionVIII Division1;1992A93ContactATS
VesselDesignConditions
PressureSafetyReleaseValve
TemperatureUniformity
PressureDisplayAccuracy
“TIME”TimerAccuracy
withthePAV’sserialnumberforacopyofthecertification.
325psig(2.24MPa)at250°F(121°C)
340 psi
±0.5°C
±1%
0.1%
“OUTOFRANGE”TimerAccuracy 0.1%
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AirInlet Male¼”NPTFitting
SolenoidValve Closedwhenpowerisapplied.In theeventofpowerloss,solenoid valvewillopenandrelease anypressureinthePAVvessel.
3.3 Environmental ConditionsOperationoftheATSPressureAgingVesselinvolvesuseofhightemperaturesandcontentsbeingcontainedathighpressure.ThelocationandplacementofthePAVshouldalwaystaketheseelementsintoconsiderationtoensureasafeworkingenvironment.ThePAVismeantforuseinlaboratory/factorysettingsinadryandcleanworkenvironment.TheworksurfacethatthePAVisplacedonshouldbeacleanandsturdyworksurfaceatareasonableworkingheightandawayfromanywater,gas,orelectricalhazards.Theworksurfaceshouldbeabletosupportmorethantheweightoftheunititself.TheindoorareathePAVisplacedinshouldbewellventilatedandcontainingnoopenflamesormaterialsthatmayconstituteafirehazard.
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Section4:UnpackingandInstallation4.1 UnpackingCarefullyunpacktheequipmentandinspectitfordamageduringshipment.Retainallcartonsandpackagingmaterialsuntiltheunitisoperatedandfoundtobeingoodcondition.Ifdamagehasoccurredduringshipping,notifythecarrierandATSimmediately.Ifitisnecessarytofileadamageclaim,retainthepackingmaterialsforinspectionbythecarrier.
4.2 Installation1.UseanoverheadcraneorforklifttoremovethePAVfromthecrateandpositionitinthedesiredlocation.
2.PositionthePAVinthetestingposition,suchasonthePAVheavy-dutysteelstandoronaworkbenchorliftcart.
CAUTION:Allsupportingandcontactingsurfacesmustbenonflammable.Donotallowflammablematerialstocontacttheshell.
3.LevelthePAVbyadjustingthescrewsonthefourfeet.
4.InspecttheO-ringseal.Makesureitiscleanandlightlycoatedwithsiliconegrease.IftheO-ringappearstobewornordamaged,contactATS.
4.3 Pan Holder Leveling1.OncethePAVisinplace,verifythattheringlocatedinsidethebottomofthepressurevesselislevelbyplacingtheparallelbarandalevelacrossthetopofthelevelingring.
WARNING:Whenplacingthelevelandtheparallelbarontothering,donotinterferewiththeRTDlocatedinthebottomofthepressurevessel.TheRTDisfactory-set
andshouldnotbemoved.
2.Ifthelevelindicatesthattheringisnotevenlybalanced,makethenecessarycorrectionsbyrotatingthethreevertical-setscrewstolowerorraisethering.Usea1/8”hexwrenchtomakethisadjustment.
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3.Afterlevelingthering,handrotatethehorizontal-setscrewsinordertosecuretheringinthebottomofthevessel.
4.4 Air and Power Connections1.Installtheairpressurelinetothe1/4”malepipe-threadedfittingprovidedonthebackofthecontrolcabinet.
CAUTION:Usearegulatedairsupplyof340to350psi(2.34to2.41MPa).Donotexceed350psi(2.41MPa)orthePAV’sperformancemaybeimpairedbyexcessive
pressure.
2.Aconnectorisprovidedwiththeunit.Thisconnectormaybechangedifitdoesnotmatchtheavailablereceptacle.Powerrequirementsare:230-240VAC,±5V,10amp,single-phase,50/60Hz.
CAUTION:ThePAVrequiresaminimumof230VACtooperatecorrectly.Checkthesupplyvoltagetoensureitis230-240VAC.Ifthesupplyvoltageislessthan
230VAC,aStep-UporBuck-Boosttransformercanbe suppliedtoprovidetheproperoperatingvoltages. ContactATS.BepreparedtoprovidetheATSService representativewithinformationabouttheavailableACvoltagesothecorrecttransformerwiringconfiguration canbeprovided.
CAUTION:ThePAVandcontrolsystemmustbegroundedaccordingtonationalandlocalcoderequirements.
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3.Ifequipped,connecttheoptionalUPSbatterybackupsupply.
a.UsethesuppliedstandardpowercordtoplugtheUPS intothewall.Thesystemshouldchargefor24hours beforeconnectingittothePAV.
b.AttachthesuppliedcordfromtheUPStothePAV.
c.Seemanufacturer’sliteratureforfurthersetup instructions.
4.ChecktheflowadjustvalveonthePAV(markedFlowControl)toensureitissetatthecorrectvalues.ThisvalvecontrolstherateatwhichthePAVdepressurizes.Whentheflowadjustvalveissetattherecommendedsetting,thePAVwilldepressurizeatoptimalrate.Theunitwillhaveasticker(seebelow)withthecorrectvalues.UsethevaluemarkedFlowAdj.
NOTE:SeeSection7forinformationonwhattodoiftheflowadjustvalvedetaches.
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4.4.1 Regulator Connections 1.Securetheairconnectiontotheairtankusingthesuppliedmaleandfemaleconnections.
2.Connectthehosetotheregulator.
NOTE:DoNOTconnectthehosetothepartmarkedFLOW.Thisisthepressurereliefvalve,andnothingshouldbeconnectedtoit.
NOTE:OutsideoftheUnitedStates,adifferentadaptermayberequired.ACGAadapterisincluded.
3.AttachthehosetothePAVusingthequickconnections.ConnectthemaleendofthehosetothefemaleconnectiononthePAVbyslidingthefemaleconnectiontowardsthePAV,connectingthehose,andreleasingtheslide.
4.Verifythatallconnectionsaretightlysealedbyapplyingsoapywaterontheconnectionsandturningontheair.Ifsudsappear,applymorecompoundortapetosealtheleak.
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Section5:Operation
PoweronthePAVbyturningtheMainPowerswitch1. locatedonthefrontofthePAVclockwisetothe“ON”position.
NOTE:Makesuretheairisconnectedandsetat340-350psiasdescribedinSection4.4.
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Software/SettingupUserLanguage2.
Select“View.”ThiswilldisplaytheInformationa. screen.ThecurrentversionofthePAVsoftwarewilldisplay.
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b. ThePAVwilldisplayitemsinEnglishasthedefaultlanguage.TochangethelanguagefromEnglishtooneofthepreprogrammedlanguages,accesstheoptionsfromthetouch-screendisplay.
Select“View”i.
Select“Language”ii.
Touchthedesiredlanguageforthedisplay.iii.
c. Select“Done”toreturntothepreheatstartupscreen.
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SettingupaBasicTest3.
Temperaturea.
Setthechambersetpointbytouchingthei. greenboxabove“ChamberSetpoint.”
Enterthesetpointtemperatureintheii. keypadthatpopsup.
Temperaturerangesare1. programmablefrom50⁰C-150⁰C;however,onlytemperaturesbetween80⁰C-115⁰Carecalibratedtobewithin±0.5⁰Cofthesetpoint.
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DoNOTenterasetpoint2. temperaturehigherthantheactualtemperaturevaluewhichwillbeusedfortheAgingProcedure.ThePAVisdesignedtooperatemostefficientlywhenthePressureVesselandSampleRackarepreheatedtothetemperatureatwhichAgingwillbedone. NOTE:AttemptingtopreheatthePressureVesseland/orSampleRacktoahighertemperaturethantheAgingproceduretemperaturemayresultineitheralongerperiodoftimerequiredforthePAVtorecovertemperatureafterPressureisappliedand/orapoorercontrolofthechambertemperatureafterpressureisappliedtothechamber.
Whenfinished,touch“ENT.” iii.
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AgingDurationb.
Setthedesireddurationtoagethei. samplesbytouching“View”andthen“Time.”Touchthegreenboxabove“DurationofTestTime.”
Entertheamountoftimedesiredforii. samplepressurizationinthekeypadthatpopsup.
Timeisprogrammablefrom1to1. 99hours.
ASTMD6521,AASHTOR28,and2. EN14769havespecifictimerequirements.Checkthelateststandardforspecifictimesiftestingtotheserequirements.
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Select“Done”toreturntothe“PreheatStartup”c. screen.
Tochangethesoaktime,selectSettingsfromthed.Informationscreen.Thesoaktimecanbesetatanytimefrom5-20minutes.
Ifusingpreheatedsamples,thesoaki. timecanbereducedtofiveminutes.Ifthesamplesareatroomtemperature,select20minutesforthesoaktime.Thiswillpreheatthesamplestotheagetemperaturepriortoaging.
TheheatersonthePAVcanbesettoautomaticallye. shutoffonceatestiscompleted.Select“On”forthisoption.Selecting“Off”willcausetheheaterstocontinuerunningafteratestiscomplete.
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Insertthef. emptypanholderintothePAVandclosethevessellid. NOTE:DoNOTloadanysamplesintothePAVatthistime. NOTE:Bolt1inthediagramisapivotboltandshouldonlybeloosenedtoallowthevessellidtoslideopenandrestonthesupportblockandtoslideclosed.Thisboltshouldnotberemoved.Forcingthisboltmaydamagetheboltassembly.
Slidethevessellidclosedandinsertbolts.Theg. boltsonlyneedtobeengagedaturnortwo.Itisnotnecessaryatthistimetocompletelytightenthebolts.Closetheovenlidandsecureusingthelatches.
PivotBolt.
DONOTREMOVE.
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Select“Off”fromthe“PreheatStartup”screenh.tostartthepreheatingprocess.WhenthePAVisheating,theHeatModewilldisplay“Heating”andaflamesymbolwillappear.
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OncethePAVhasreachedthesetpoint,thedisplayi. willprompttheoperatortoinsertthespecimens,securethelid,andselect“Age.”
Carefullyremovethespecimenholderi. fromthePAVasitwillbeveryhot. NOTE:ThePAVneedstoexperienceheatlosssoitknowswhattodoafter“Age”isselected.Ifitdoesnotexperienceheatloss,thePAVgetsconfusedanddoesnotknowwhattodonext.ThisheatlossshouldhappenwhenthespecimensareloadedintothePAV.
Leavethevessellidopen.ThePAVisii. designedtorecoverfromtheheatlossduringthisstage.Ifthevessellidisclosedandthetemperaturedoesn’tdropenough,thePAVmaygiveerraticresultsandhaveadifficulttimerecoveringtothesetpoint.
Loadspecimensintorack.iii.
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Loadalltenpansintothesample1. holdereveniftherearenottensamplestoage.
Quicklyandcarefullyreturnthesampleiv. holdertothePAV.Thevesseltemperaturewilldecreasewhentheovenandvessellidsareopen.Toavoidalongtemperaturerecovery,attempttoloadthePAVandsecurethevesselandovenlidsasquicklyandassafelyaspossible. NOTE:DonotloadsamplesintothePAVuntilthePAVisheatedtothesetpointandthe“PreheatReady”screenisdisplayed.
Closethevessellidandsecuretheboltsv. accordingtothediagram.
Tighteninsequentialorderwiththevi. wrenchprovided.Goaroundtwicetotightenboltsto55inch/pounds.
PivotBolt.
DONOTREMOVE.
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Oncethevessellidissecured,closetheovenlidj.andsecurewiththelatches.
Immediatelyk. select“Age”fromthetouchscreen.DonotwaitforthetemperatureinthePAVtorecovertothesetpointpriortoselecting“Age.”
Thedisplaywillthenresembletheimagebelowl. andwillattempttorecovertheheatlostduringspecimenloading.
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Withintwohoursofselectingthe“Age”function,m.thePAVtemperaturewillrecoverthetemperaturelostwhileloadingthesamples.Whenthetemperaturerecoverstowithin0.3°Cofthesetpointtemperature,anapproximate20-minutedelaywillbegin.Thisisbuiltintothesoftwaretoallowthechambertemperaturetostabilize. Followingthis,thePAVwillbegintopressurize.ThetimerontheAgingHeatUpscreenwilldisplaythetotaltimefromwhenthe“Age”buttonwaspresseduntilthePAVstartstopressurize.WhenthePAVhaspressurizedtoslightlyabove2.00MPa,theagingcyclewillautomaticallybegin.Thescreenshownatthistimewillresemblethe“AgingPressurized”screen.
IfthePAVdoesnotreachthesetpointandi. pressurizewithinthetwo-hourtimeframeorhasdifficultyreturningtothesetpointafterpressurizing,checkthatthepowertothePAVis230-240volts.230voltselectricityistheminimumrequiredforthePAVtooperatecorrectly.
Ifthepowersupplyis230-240voltsand thetemperaturehasnotrecovered, verifythefollowing:
Besurethatthevessela. lidremainsopenwhenloadingsamplepansintothesampleholder.
Verifythatthesamplesareb.notbeingheatedabovethePAVsetpointpriortoinsertingthemintothePAV.
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Verify“Age”wasc. selectedfromthetouchscreenimmediatelyafterloadingthesamples,securingthevessel,andlatchingthelidasdescribedintheprevioussteps.
IfthePAVreturnstothesetpointbutii. doesnotpressurizecompletely,checkthattheairlineisconnectedandopentoallow340-350psiofairflow.
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Oncethisscreenappears,theCurrentErrorTimen. counterwillbegintocount.TheCurrentErrorTimecounterwillcontinuetocountuntilthechambertemperatureiswithin±0.5°CoftheChamberSetpoint.TheAccumulatedErrorTimecounterdoesnotincrementuntiltheCurrentErrorTimecounterstopscounting.Atthattime,theCurrentErrorTimecountervaluewillbeloadedintotheAccumulatedErrorTimecounter.IfthetemperatureorpressureinsidethePAVgoesoutsideoftheallowablelimits,theCurrentErrorTimecounterwillresetandbegincountinguntilthetemperatureand/orpressurehasreturnedtowithinallowablelimits,andtheAccumulatedErrorTimecounterwillagainbeupdated.TheAccumulatedErrorTimecounterwillonlyupdateaftertheCurrentErrorTimecounterhasquitcounting. NOTE:ItispossiblethattheCurrentErrorTimecounterwillcontinuetocountforseveralsecondsormorewhentheChamberTemperaturedisplayediswithin±0.5°CoftheChamberSetpoint.ThisisnormalandisduetothefactthattheChamberTemperaturedisplayis1decimalpointofprecisionandisroundedup,whiletheerrortimeisbasedon3decimalpointsofprecision.
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OncethePAVispressurized,itispossibletoselecto.“Graph”toseeagraphofreal-timedatabeingcollected.
Whenfinished,select“Done”toreturntothep. previousscreen.
Oncethetestiscomplete,thedisplaywillq.changetoresembletheonebelow.Pressurewillautomaticallyreleaseinanapproximatelinearstate andthePAVwillremainatthepreheatedtemperatureuntilthe“Reset”buttonispressed.
Ifthepressuredoesnotreleasewithinthei. allowabletimespecified,checkthattheflowadjustvalvelocatedonthefrontofthePAVisopentothenumberstatedonthecalibrationsticker.
Todownloaddata,select“Done”fromtheii. AgingCompletescreenandthen“Data”fromtheinformationscreen.
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InsertastoragedeviceintotheUSBportiii. onthePAV. NOTE:AwindowwillappearanytimeastoragedeviceininsertedintotheUSBport.Donotpressanythingatthistime.Thewindowwillcloseaftertenseconds.
Afterthewindowcloses,select“Backupiv. DataUSB1.”
Datawillbesavedasa.CSVfile1. thatcanbeimportedtoMicrosoftExcel®. NOTE:The.csvfilescreatedusetheUSsystemofacommaasthedelineator.
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SettingupAutomaticStart4.
FromthePreheatStartUpscreen,select“View”a. andthen“Time”toreachthescreenthatwillallowoperatorstosetupthePAVtostartautomatically.
Setthecurrenttimeanddatebyselectingtheb.greenboxesandsettingthecurrentvaluesinthe“SetClockCurrentTime”box.
SetthetimeanddateforthePAVtostartc. automaticallyinthe“SetHeatStartTime”box.
Select“TimerDeactivated”toturnthetimerond.andenableautomaticpreheatatthetimeanddateimputed.
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SettingupRemoteCommunication5.
ThePAV3isnetwork-readyandcanbeviewedanda. controlledwithVNCViewersoftware.ATSstronglyrecommendscontactinganetworkadministratortosetupthisfeature.
UsingVNCViewersoftwarerequirestwoIPb.addresses(within1/100ofeachother),asubnetmask,andagatewayforeachPAV3onthenetwork.
HMIIPAddress:____.____.____.____i.
RMIPAddress:____.____.____.____ii.
SubnetMask:____.____.____.____iii.
Gateway:____.____.____.____iv.
TheHMIIPAddressistheaddressofthetouchc. screencontroller.
TheRMIPAddressistheaddressoftheRMinsided.ofthePAV.Thesetwoaddressesneedtobewithin1/100ofeachothertocommunicate.
Defaultsettingsare:i.
HMIIP:172.16.1.991.
RMIP:172.16.1.1002.
Sub:255.255.255.03.
CheckIPaddressesandsettingsine. three places.
i. OnthePAVdisplay,pressView/Languagesmenu.
1. Checkthedifferentlanguages andtheIPaddresses: HMI-172.16.1.99and RM-172.16.1.100.
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2. Thesesettingsmayneedtobe entered.
3. Check/setthedateandtime.
ii. OnthePAVdisplayscreen,usethe“Settings”icon.Thisisageariconthatappearsinthelowerrightcornerafterthearrowispressed.
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1.Enter“1”sixtimesonthe“virtual keyboard.”
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2.FindtheNetworkTabandmakesurethe spotfor“IPaddressgetfrombelow”is selected.
3.FillinthecorrectnumbersfortheIP address.172.16.1.99isthedefaultIP address.Thesubnetmaskshouldbeleft as 255.255.255.0.
4.GototheVNCServertab,itisthe secondtothelasttabandensure “StartVNC”isgreyedout.Ifitis not,selectittoenabletheVNCViewer toconnect.
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iii.OntheWatlowEZ_ZoneController: 1.OpenthesidepanelofthePAV.
2.FindtheRUIinside;itwilllooklikethe picturebelow:
NOTE:TheRUIhasmanysettings.Settings thatarenotmentionedintheinstructions shouldnotbechanged.Changesto anyothersettingsmaycausethemachine tofunctionimproperly.
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3.Pressthebottomtwobuttons simultaneously(theAdvancekeyand theDownkey)forthreesecondsuntil thedigitaldisplayshowsCOMin theupperdisplayandrUiinthelower display.Thecommunicationmenu shouldappear.
NOTE:UsetheUpandDownkeystomove throughthemenus.TheInfinitykeygoes backonemenulevel,theAdvancekey selectsamenu.
4.PresstheAdvancekeyonlyuntilCom1 appears.
5.Usetheuparrowtochangethisto Com2andusetheAdvancekeyto selectthismenu.
a.iP.F1isthefirstsetofnumbers intheIPaddress.UsetheUp andDownkeystochangethis valuetothedesiredvalue. Thedefaultvalueis172.Select theAdvancekeywhen complete.
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b.iP.F2isthesecondsetof numbersintheIPaddress.Use theUpandDownkeystochange thisvaluetothedesiredvalue. Thedefaultvalueis16.Select theAdvancekeywhen complete.
c.iP.F3isthethirdsetofnumbers intheIPaddress.UsetheUp andDownkeystochangethis valuetothedesiredvalue.The defaultvalueis1.Selectthe Advancekeywhencomplete.
d.iP.F4isthefourthsetof numbersintheIPaddress. UsetheUpandDownkeysto changethisvaluetothe desiredvalue.Thedefaultvalue is100.SelecttheAdvancekey whencomplete.
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e. Thesubnetcanbechangedthe samewayastheIPaddress. iP.FS1,iP.FS2,iP.FS3,andiP.FS4 arethevaluestochangethe subnet.Thedefaultvaluesare 255.255.255.0.Usethe Advancekeytocyclethrough theseoptionsandusetheUp andDownkeystochangetheir values.
f.Onceallchangeshavebeen made,holdintheInfinitykey fortwosecondstoreturnto thehomepage.
g.Onceallthevalueshavebeen enteredinthePAVunderthe languagessection,underthe settingssection,andintheRUI, poweroffthePAVandthen turnthePAVonagain.Ifa yellowerrorboxdisplays, checkthattheIPaddressesare within1/100ofeachotherand thesamevalueshavebeen enteredinallthreeplacesin thePAV.
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Section6:Verification6.1 Verifying TemperatureToverifytemperature:
1.Placethetemperatureprobeinsidethecalibrationblock.NotetheinsideofthePAVafterthepanholderisremoved.
NOTE:ThiscalibrationblockisfromtheATSPAVVerificationKit.SeeSection8.3.
2.PlacetheotherholeinthecalibrationblockovertheRTDon thebottomofthevessel.OncetheblockissecureontheRTDandthetemperatureprobe,slidethePAVlidclosed.Useasmallwrenchorpopsiclesticktokeepthelidfrompinching thewireonthetemperatureprobe.DONOTBOLTTHE LIDDOWN.
3.Verifythetemperature.
a.SetupthesetpointandstartthePAV.
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b.Verifythatthetemperaturedisplayonthethermometer matchesthetemperaturedisplayon thePAV.Allowtemperaturetoreachsetpointand stabilizeforonehour.
c.NoteanydifferenceandcallATSforcalibrationorusethedifferencetooffsetfuturetests.
NOTE:Donotverifytemperatureandpressureatthesametime. 6.2 Verifying Pressure
Toverifypressure:
1.Removethescrewintopofthevessellid.
2.Screwthepressuregageintothatspace.Makesurethelidis securedaccordingtothedirectionsinSection5.
3.ApplythepressuretothePAV.Allowpressuretoreach2.10.1MPaandstabilizeforfifteenminutes.
4.Verifythatthedisplayonthepressuregagematchesthe displayedpressureonthePAVdisplay.
5.NoteanydifferenceandcallATSforcalibrationifthedifferencefallsoutofspecification.
NOTE:ItisbesttohavethePAVsetpointatalowtemperatureandtheSoakTimesetforfiveminutes.
NOTE:Donotverifytemperatureandpressureatthesametime.
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Section7:Troubleshooting7.1 Temperature Does Not Recover to Setpoint
Check that the PAV is receiving 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 vessel lid open while loading specimens in
pan rack?
NO YES
The PAV is designed to recover the heat
lost. Leave the vessel lid open
See notes on following page
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7.2 Troubleshooting the PAV ControllerThePAV3wasdesignedtoallowformaximumuserflexibilitywhilealsomeetingthecurrentASTM,AASHTO,andENspecifications.Thecontrollerisprogrammedtorespondtospecificsituationstoallowforallofthesecriteriatobemet.
OptimumAgingPerformanceisachievedbyfollowingthesesteps:
1.PreheatthePAVandemptythesampleracktothedesired conditioningtemperature.
2.WhenPAVshowsthePreheatReadyscreen:
a.Removethehotsamplerack.
b.Leavevessellidopen.
c.Loadsamplesintothesamplerack.
d.Placesamplerackinsidethepressurevessel.
e.Closelidandsecureboltsasdescribed.
f.Press“Age”immediatelyafterlidissecuredtobeginthe automaticagingprocess.DoNOTwaitfortemperature ofthePAVtorecovertothesetpointbeforepressing “Age”button.
3.DoNOTpreheatsamplespriortoplacinginPAVtoa temperaturehigherthanthetemperaturetobeusedtoagethesamplesinthePAV.Itisrecommendedtouseroomtemperaturesamples.Thebuilt-insoaktimewillpreheatthesamples accordingtospecification.
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7.3 Reattaching the Flow Adjust ValveIntheeventtheflowadjustvalvedetaches,pleaseusethefollowingstepstocorrectit.
1.Theflowadjustvalvehasthreeparts:theshaft,thebrasscollar,theadjustmentknob.
2.Thebrasscollarfitsovertheshaft,andtheadjustmentknobfitsoverthebrasscollar.Ifthebrasscollarisnotvisible,checktheinsideoftheadjustmentknob.Ifitisinsidetheadjustmentknob,usea1/16in.hexwrenchtoloosenthescrewinthe adjustmentvalvesothebrasscollarcanberemoved.
3.Rotatetheshaftfullyclockwisetoclosetheflowadjustvalve.
4.Placethebrasscollarbackontheshaftandensureitisagainstthevernierbarrel.Usea1/16in.hexwrenchinsertedintotheholeshownbelowandtightenthebrasscollarontotheshaft,ensuringitstaystightlyagainstthevernierbarrel.
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5.Lineuptheadjustmentknobwithzeroat12o’clock,andinsertoverthebrasscollarandtothelastlineofthevalvebody.Usingthe1/16in.hexwrench,insertintotheholeasshownbelowandtighten.
6.Turnthevalveslowlycounter-clockwisetoopen.Eachfullrotationshouldequalonelineonthebarrel.Rotatetheknobtothevaluerecordedonthecalibrationsticker.Ifthereisnovalueonthecalibrationsticker,thedefaultvalueis10.
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7.4 Updating the Software1.PowerupPAV3fromthefrontpanel.
2.UnscrewUSBportcoverandinstallflashdrivecontainingtheupdatedversionsoftwareintotheUSBport.
3.Inafewseconds,amenuwillpopup.ChooseDownload.
4.Anotherpop-upmenuwillappearpromptingforaPassword.Usingthekeyboarddisplayedonthescreenbelow,type 111111andselectOK.
5.Thenextscreenthatappearswillhave3options.
a.√ChecktheboxthatindicatesDownloadProjectFiles.
b.Unchecktheboxes:
i.ClearHistoryFiles.
ii.DownloadHistoryFiles.
6.Twosubdirectorieswillappear:pccardandusbdisk.
a.Selectusbdisk.
b.Selectdisk_a_1.
c.SelectOK.
7.Thenecessaryfileswillnowbedownloaded.
8.SelectView.
9.Atthetopofthescreen,thecurrentversionofsoftware shouldbeindicated.
10.SelectDone.
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11.VerifyIPaddresssettingsbyselectingView,thenLanguage.
12.Alllanguagesshouldhavethefirstrowindicating172,16,1,99andthesecondrowindicating 172,16,1,100unlesschangesweremadetosetupremotecommunication.Ifchangesweremadetosetupremote communication,verifythesettingsarecorrect.Ifnot correct,selecttheappropriatefieldandenterthecorrectsetting.
13.Thesoftwareupdateisnowcompleted.
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Section8:Maintenance8.1 Preventive Maintenance1.Keepthepressurevessellidboltslubricatedusingananti-seizeagent.Repeatedinsertionandextractionofstainlesssteelboltsinastainlesssteelvesselwithoutusinganti-seizepastecan causegalling.Lowerspeedinsertionandextractionofboltscanalsohelptopreventgalling.Use¼to½thespeedfor steel in steel.
2.PeriodicallylubricatetheO-ringwithsiliconelubricant.The O-ringismadeofsyntheticrubberandislocatedinthepressurevesselflange.DamagedorwornO-ringsshouldbereplacedwiththesamematerial.
8.2 Changing Fuses1.ControlCircuitFuse:Thecontrolcircuitfuseisa2amp,250volt5mmx20mmBUssmannGMA(orequivalent)fuse.Itislocatedattheleftrearofthesystem.
2.HeaterCircuitFuse:Theheatercircuitfuseisa10amp,250voltsemiconductor-typeBUssmanGMA2A(orequivalent)fuse.Itislocatedinsidetheleftcontrolcabinet.Iftheheatercircuitfuseshouldmalfunction,contacttheATSServiceDepartmentat+1-724-283-1212forinstructionsonhowtoservicethisfuse.
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8.3 Spare PartsSomepartsaresuppliedfromoutsideATS.Refertomanufacturer’sliterature.
ConsumablesPartNumberPAV1045PAV-PAN-KITPAV-LUBEPAV1038PAV1044PAV1068PAV1070PAV1072
AccessoriesPartNumberPAV-115-SU-TRANS
DescriptionPAVO-RingSetOf(10)SpecimenPansAnti-SeizeLubricantFuse,2A5X20MMSlowBlowF2 Fuse,10Amp250VoltLed,Tri-ColorDiffusedLed,RedDiffused4Led,GreenDiffused3
DescriptionStep-UpTransformer-Enablescustom-erswithpowerof115VAC,1Ph,60Hz,10AMPtooperatePAV(powerrequire-mentsof240VAC,1Ph,50/60Hz,10AMP.)
PAV-BUCK-TRANS BuckBoostTransformer-Increasesexisting208voltsto230volts
PAV-UPS-BU UPSBatteryBackUpSystem-PreventsPowerFailures,Sags,Surges,UnderandOverVoltages.
PAV-VER-KIT PAVVerificationKit-Includescalibrationblock,thermometricdevice,andpressuregage
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AccessoriesPartNumber DescriptionPAV-VER-KIT-NIST NISTPAVVerificationKit-Includescali-
brationblock,NISTcertifiedthermometricdevice,andNISTcertifiedpressuregage
PAV-STAND PAVSteelStand-StandforPAVPAV-CART HydrolicLiftCart-foreasyheightadjust-
mentofthePAVPAV-LEVEL Levelwithparalellbar101521 RTDThermometerW/Probe,Nist100068 DigitalPressureGage-NIST100065 Thermometer100067 ImmersionProbeRTD-usewith100065100069 Digital Pressure GagePAV-CAL-BLOCK CalibrationblockforPAV
SparePartsPartNumber DescriptionPAV-SS-REG-Europe SingleStageRegulatorforuseinEuropePAV-SS-REGULATOR SingleStageRegulatorPAV-WRENCH Wrench,HexSocket1/2InDrivePAV1148 LevelingRing,4-8310,Rv.2,It1PAV9012 Tool,PanHandlingPAV9015 Adapter,CGAPAV9016 Wrench,HexSocket1/2InDrivePAV9017 Wrench,Allen1/8InchPAV9020 Hose,HighPressureAssyPAV-PAN-HOLDER PAVSpecimenRack
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AppendixA:Warranty
WarrantyStatementYourAppliedTestSystemsproducthasbeenmanufacturedandinspectedbyexperiencedcraftsmen.AppliedTestSystemswarrants,fortheoriginalpurchaser,eachproducttobefreefromdefectsinmaterialandworkmanshipforaperiodofthirteen(13)monthsfromdateofshipmentortwelve(12)monthsfromdateofinstallationwhichevercomesfirst.Thiswarrantydoesnotapplytofailurescausedbynormalusage,misuse,orrepairorservicebyunauthorizedpersonnel,nordoesitcoverlimitedlifeelectricalcomponentswhichdeterioratewithagesuchastubes,lamps,fuses,andheaters.ThewarrantydoesnotextendtoproductsnotmanufacturedorassembledbyAppliedTestSystems.
Thiswarrantyisexpresslylimitedtotherepair,replacement,oradjustmentoftheproductatAppliedTestSystems’option.TheproductmustbereturnedtotheAppliedTestSystemsfactoryoranauthorizedrepaircenter.AppliedTestSystemsshallnotbeliableforanylabor,transportation,orinstallationcoststhatmayariseinconnectionwiththeproductorreturn.
Toobtainwarrantyservice:
1.AppliedTestSystemsmustbepromptlynotifiedinwritingof thedefect.
2.Uponreceiptofwrittenauthorization,saiddefective equipmentisreturnedasdirected,withtransportation chargesprepaidbythebuyerand–
3.AppliedTestSystemsexaminationofsuchequipmentdiscloses toitssatisfactionthatthedefectexistsandwasnotcaused bynegligence,misuse,improperinstallation,accident,or unauthorizedrepairoralteration.
Thiswarrantyisinlieuofallotherwarranties,expressedorimplied,includingtheimpliedwarrantyofmerchantabilityorfitnessforparticularpurpose.InnoeventshallAppliedTestSystemsbeliablefordirect,indirect,special,incidental,collateralorconsequentialdamages.
TheaforementionedprovisionsdonotextendtheoriginalwarrantyperiodofanyarticlethathasbeeneitherrepairedorreplacedbyAppliedTestSystems.
AppliedTestSystemsreservestherighttochangepublishedspecifications.
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154EastBrookLane|Butler,PA16002USA|+1-724-283-1212|www.atspa.com