Pressure Aging Vessel PAV3

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

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.

49

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.

52

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

53

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

54

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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