Ametek CHANDLER ENGINEERING Twin UCA 4262 User manual

Model 4262
Twin UCA
Operating Manual
Revision AA – March 2016
P/N 84-0005
S/N _____________
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Copyright © 2016, by Chandler Engineering Company, LLC
All rights reserved. Reproduction or use of contents in any manner is prohibited without express permission from Chandler Engineering Company L.L.C.
While every precaution has been taken in the preparation of this manual, the publisher assumes no responsibility for errors or omissions. Neither is any
liability assumed for damages resulting from the use of the information contained herein.
This publication contains the following trademarks and/or registered trademarks: AMETEK, CHANDLER ENGINEERING. These trademarks or
registered trademarks and stylized logos are all owned by AMETEK, Inc. All other company, product and service names and logos are trademarks or
service marks of their respective owners.
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TABLE OF CONTENTS T-1
Table of Contents Page
General Information................................................................. P-1
Description of Instrument ...................................................................................................... P - 1
Features .................................................................................................................................. P - 1
Instrument Specifications ....................................................................................................... P - 1
Section 1 - Installation .............................................................. 1-1
Unpacking the Instrument ...................................................................................................... 1-1
Utility Requirements .............................................................................................................. 1-1
Tools/Equipment Required .................................................................................................... 1-1
Safety Requirements .............................................................................................................. 1-1
Setting up the Instrument ....................................................................................................... 1-2
Connecting Power ............................................................................................................ 1-2
Connecting Water Supply Lines ...................................................................................... 1-2
Connecting the Drain Lines ............................................................................................. 1-3
Connecting Air to Instrument .......................................................................................... 1-3
Section 2 – Operating Instructions .......................................... 2-1
Front Panel Controls .............................................................................................................. 2-1
Pump Pressure Adjust Regulator .......................................................................................... 2-1
Pump Pressure Gauge ............................................................................................................ 2-2
Pressure Relief Valve ............................................................................................................. 2-2
Pump Switch .......................................................................................................................... 2-2
Pressure Valve Left/Right ...................................................................................................... 2-2
Cooling Water Switch Left/Right .......................................................................................... 2-2
Pressure Release Valve .......................................................................................................... 2-2
Cylinder Pressure Gauge Left/Right ...................................................................................... 2-3
Temperature Controller Left/Right ....................................................................................... 2-3
Heater Switch Left/Right ....................................................................................................... 2-3
Main Power Switch ............................................................................................................... 2-3
Top Transducer Connector .................................................................................................... 2-3
J Thermocouple Connector .................................................................................................... 2-3
Rear Instrument Panel ........................................................................................................... 2-4
Main Power Connection ........................................................................................................ 2-4
Serial RS232/RS485 Connections ......................................................................................... 2-4
Preparing the Instrument for a Test ....................................................................................... 2-5
Programming the Temperature Controllers ..................................................................... 2-5
Setting Up the Test Cell......................................................................................................... 2-5
Preparing the Test Cell .......................................................................................................... 2-6
Running a Test ....................................................................................................................... 2-7
Pressure Control .............................................................................................................. 2-7
Starting the Test ............................................................................................................... 2-7
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T-2 TABLE OF CONTENTS
Ending the Test ............................................................................................................ 2-8
Cleaning the Test Cell ........................................................................................................ 2-8
Section 3 - Maintenance and Servicing ................................... 3-1
Maintenance ...................................................................................................................... 3-1
7 Micron Filter Replacement ........................................................................................ 3-1
Regulator Rebuild Instructions ..................................................................................... 3-1
Major Disassembly ................................................................................................. 3-2
Bonnet Disassembly/Reassembly ............................................................................ 3-2
Sensor Disassembly / Reassembly ........................................................................... 3-2
Major Assembly ..................................................................................................... 3-3
Section 4 - Troubleshooting Guide .......................................... 4-1
Section 5 – Replacement Parts ................................................ 5-1
Section 6 - Drawings and Schematics ...................................... 6-1

PREFACE P-1
General Information
Description of Instrument
The 4262 Ultrasonic Cement Analyzer is an instrument that is used to test a cement sample at
elevated temperature and pressure for the purpose of predicting compressive strength of the
cured cement.
Features
The major features of the 4262 Ultrasonic Cement Analyzer are listed below:
•Easy to install and use
•Compact, bench top design
•Twin cells for conducting two simultaneous tests
•Interface to Chandler Engineering 5270 Data Acquisition System
•Ramp and Soak temperature controllers
•Integral pump and relief valve for pressure control.
Instrument Specifications
• Maximum Curing Temperature: 400°F (204°C)
• Maximum Curing Pressure: 5,000 psi (35 mPa)
Mechanical and Electrical
• Input Voltage: 220 ±15% VAC, 50/60 Hz, 8A.
• Heater: Four heaters at 350 W each
Environmental and Utility
•Operating Temperature: 40-120°F (0-50°C)
•Compressed Air: 75-125 psi (618 to 963 kPa)
•Pressurized Water: 20-80 psi (138 to 552 kPa)
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P-2 PREFACE
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SECTION 1 – INSTALLATION 1-1
Section 1 - Installation
Unpacking the Instrument
After the consistometer is unpacked, the operating equipment and spare parts on the packing
list should be checked to affirm that all have been received and none are damaged.
File an insurance claim with your freight carrier if damage has occurred during shipment.
Utility Requirements
Your unit will require dry, oil free compressed shop air (not instrument quality) of 75 to 125
psi (618-963 kPa), and a water supply of 20-80 psi (138-552 kPa). The unit is capable of
operating in ambient temperatures from 40°F to 120°F.
Tools/Equipment Required
A standard maintenance or mechanics tool set is adequate for the installation, operation, and
maintenance of the instrument. No special tools are required.
This unit is supplied with an installation kit, which includes the necessary hardware for the
water, air, and electrical hook-ups. The water and air hose may be cut to length and the
appropriate barbed fittings inserted into the hose and clamped into place.
Caution: The laboratory electrical power wiring must be capable of a 15-ampere
load and comply with local electrical codes. The instrument must be
securely connected to an appropriate earth ground. The ground wire
must have a larger diameter than that of the supply voltage conductors.
Safety Requirements
Warning: Read before attempting operation of instrument.
This instrument is capable of extremely high temperatures and
pressures and must always be operated with CAUTION. The
instrument is designed for operator safety. To ensure of that safety it is
essential to follow the instructions outlined below.
The following safety procedures are advisable:
• Locate the instrument in a low traffic area.
• Post signs where the instrument is being operated to warn other personnel.
• Read and understand the instructions and caution notes before attempting operation.
• Always close the pressure valve before disconnecting the quick-connect fitting to
prevent water from being forced out and spraying directly on operator.

1-2 SECTION 1 – INSTALLATION
• Never exceed instrument maximum pressure and temperature ratings. Disconnect the
main power to the instruments during service or repair operations.
• Always operate instrument with back panel in place.
• Turn off the heater at the completion of a test. Hot water in the open cylinder or
drain, when exposed to the atmosphere and heated beyond its boiling point, can cause
server burns from steam.
• During a test the enclosure, especially the area around test cells, can become extremely
hot and cause injury
• A fire extinguisher, type 8 BC, should be located within 50 feet (15 meters) of the
instrument.
• Have the safety officer at your location or laboratory review the safety aspects of the
instrument and installation and approve the operational and installation procedures.
Setting up the Instrument
Connecting Power
The 4262 instruments have one connection for input power. Connect power to the instrument
using the cord supplied with the instrument. Connect each individual instrument to a separate
circuit breaker or fuse. (A 15 Amp fuse or circuit breaker is recommended.)
Connecting Water Supply Lines
All fittings on the instruments’ back panel are 1/4” female N.P.T. The included accessories kit
contains the hose connectors necessary for installation.
Refer to 84-0006 Plumbing Schematic, found in Section 6 – Drawings and Schematics, for
suggested plumbing hook-ups.
Connect the water supply line to the connector labeled WATER IN and COOLANT IN on the
rear panel of the instrument. The water must be clean and free of debris that could cause
failure of the pump or relief valve. A coarse water filter is supplied in the installation kit. If in
doubt, an additional water filter is recommended.
If the optional chiller is being used, connect the outlet port of the chiller system to the
COOLANT INLET port and the COOLANT DRAIN port to the chiller inlet port. Configure
the chiller to operate at the minimum set-point temperature (41°F, 5°C).

SECTION 1 – INSTALLATION 1-3
Connecting the Drain Lines
Connect the water drain line to the connector labeled WATER OUT and COOLANT OUT on
the rear panel of the instrument.
The drain system must be capable of handling hot water up to 212°F (100°C) or brief surges
of up to 400°F (204°C) steam for short periods of time during initial cooling of the
instrument. If two or more instruments are connected to a common drain line, it is
recommended that the common drain be 3/8-inch (10mm) inside diameter, minimum.
Note: Do not discharge ethylene glycol solutions into the drain since it is
considered an environmentally harmful substance. Dispose of used
solutions as recommended according to the M.S.D.S.
ConnectingAir to Instrument
Connect the air supply to the connector labeled AIR INLET on the rear panel of the
instrument as shown in the preceding figure. The fitting is a 1/4-inch female N.P.T. fitting.
Compressed nitrogen may also be used in place of the compressed air if necessary.

1-4 SECTION 1 – INSTALLATION
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SECTION 2 – OPERATING INSTRUCTIONS 2-1
Section 2 – Operating Instructions
Front Panel Controls
The figure above shows the front panel and all the associated controls. The description of
each control is described below.
Pump Pressure Adjust Regulator
This regulator is used to control the pressure of the air supplied to the pump, which is directly
proportional to the hydraulic pressure output of the pump. As the air pressure increases, the
hydraulic pressure increases. Turn the regulator knob counterclockwise to decrease air
pressure to the pump, clockwise to increase the air pressure.
If the regulator is set to a value and the pump switch is turned to the ON position, the pump
will increase pressure until the pneumatic force of the air (air pressure multiplied by pneumatic
piston area) equals the hydraulic force of the pressurizing water (water pressure multiplied by
pump piston area). At this point the pump will cease to stroke. If the water pressure falls for
some reason, a force imbalance will be created between the pneumatic and hydraulic sides of
the pump and the pump will begin to stroke and increase the hydraulic pressure until it is
balanced with the pneumatic pressure, then it will again stop pumping. In this way, the pump
may be used as a pressure control device (combined with the relief valve) to establish the
lower pressure limit for a test. This will be discussed further in the section Running a Test.

2-2 SECTION 2 – OPERATING INSTRUCTIONS
Pump Pressure Gauge
Indicates the pressure of the water supplied from the pump. May be changed, as discussed in
the paragraphs above. Each 5 psig (35.5 kPa) pressure applied to the pump results in
approximately a 355 psi (2450 kPa) hydraulic pressure output from the pump.
Pressure Relief Valve
The relief valve or back-pressure regulator may be used to set the upper limit on the system
pressure up to 5,000 psig. Turn the relief valve knob clockwise to increase pressure and
counterclockwise to reduce pressure. The use of the pump and relief valve to control pressure
automatically will be discussed in the section titled Running a Test.
Pump Switch
Opens or closes a solenoid valve which controls the flow of air to the pump. Turning this
switch to the ON position causes the pump to maintain or increase pressure in the test cell.
Turning the switch to the OFF position stops the pump from operating.
Pressure Valve Left/Right
This valve is used to control the flow of water from the pump and test cell and must be closed
any time the test cell is not installed. T he valve must be open to fill the tubing connected to
the test cell with water or to operate the pump. Opening this valve when the test cell is not
installed will cause a significant water leak.
Caution: Close the valve before disconnecting the quick-connect fitting to
prevent water from being forced out and spraying directly on operator.
Cooling Water Switch Left/Right
This valve is used to control the flow of cooling water to the heating/cooling jacket. This
switch must be off during a test, but should be opened following a test to cool the heater and
test cell. With the Auto Cooling option, this switch can be set to Auto to allow the
temperature controller to control the coolant valve. This is useful for tests where the sample
must be below ambient temperature.
Pressure Release Valve
The valve must be closed during testing except when it is necessary to manually release
pressure. The valve must also be closed when removing test cell with cooling water ON or
else a significant water leak will occur.

SECTION 2 – OPERATING INSTRUCTIONS 2-3
Cylinder Pressure Gauge Left/Right
Displays pressure inside the test cell.
Temperature Controller Left/Right
Controls temperature inside the test cell.
Heater Switch Left/Right
Turns the heater ON or OFF. Switch must be in the ON position during testing and should be
in the OFF position as a safety precaution at other times.
Main Power Switch
Turns power to the entire instrument ON or OFF. Switch must be in the ON position during
testing.
Top Transducer Connector
The coaxial connector attached to the top transducer must be connected to this connector
prior to the beginning of a test.
J Thermocouple Connector
The thermocouple that is attached to the top plug must be plugged into this connector prior to
the beginning of a test and any time that it is necessary for the temperature controller to
operate. If the thermocouple is not connected, the temperature will display 5.br and will not
function.

2-4 SECTION 2 – OPERATING INSTRUCTIONS
Rear Instrument Panel
The rear panel contains all the connections for the cables that connect the instrument to the
processor.
Main Power Connection
Located on the rear instrument panel is an IEC-320 STD C13 connector.
Serial RS232/RS485 Connections
The rear panel contains all of the connections for the RS-485/RS-232 communications ports
used to connect several instruments in one 4262 UCA System.

SECTION 2 – OPERATING INSTRUCTIONS 2-5
Preparing the Instrument for a Test
Prior to running a test, the following steps must be performed.
Programming the Temperature Controllers
Refer to the Chandler Engineering Model 8050 Temperature Controller Manual for complete
information on how to program and operate the temperature controller.
Setting Up the Test Cell
The steps that should be used to set up the test cell are listed
below.
Warning: The plugs and vessels are not interchangeable
without voiding the pressure vessel certification.
Any replacement of the top plug, bottom plug, or
vessel, requires a new hydrostatic test certification.
Note: If cement sets in the threads during a test, the plug
may be extremely difficult to remove.
• Replace the O-ring seals on the top and bottom plugs after
each test. The brass back-up ring must be on the side of the
O-ring closest to the threads on the plug (see drawing 84-
0045).
• Always double-check the sealing components to make sure
they are clean and in good condition.
• Apply a light coating of lithium grease to the inside cylinder and threads and also to each
plug. This will prevent cement from sticking to the metal and will make cleanup easier.
Avoid applying grease on the flat face of the plugs, as they will affect the transducer
signal.
The test cylinder is tapered from top to bottom, with the smallest diameter at the top. This is
to facilitate removal of the cement sample from the test cell. The top of the cylinder is
denoted by the letter “T” stamped on the wrench flat on the top end of the cylinder.
• Place the cylinder in a vise with the bottom end up using the wrench flats on either end of
the cylinder. Use caution when placing the cylinder in the vise and do not damage the
cylinder by tightening the vise excessively, or clamp the cylinder any place other than the
flats on either end of the cylinder.
• Make certain the sealing components are properly installed on the bottom plug. Apply a
liberal coating of high temperature grease on the o-ring.

2-6 SECTION 2 – OPERATING INSTRUCTIONS
• Screw the bottom plug into the bottom of the cylinder. It is important that the plug be
tightened so that it just contacts the top of the cylinder. Further tightening after the plug
has contacted the cylinder will not cause more effective sealing and will cause p lug
removal difficulty, as well as severe damage to the cylinder and end caps.
Preparing the Test Cell
The recommended steps in preparing the test cell and slurry for testing are outlined in the
following steps.
• Pour approximately 200cc of cement slurry into the greased test cell. Be careful not to
get cement into the threads. If cement sets up in the threads it may make plug removal
and installation difficult.
• Continue to pour cement into the test cell until level is 1/4 inch (6mm) below the circular
lip in the cylinder. Alternately, you can use the Slurry Level gauge provided with the
instrument. The slurry should touch the lower tab marked WET but not touch the upper
tab marked DRY. Do not overfill the test cell or cement will be forced into the pressure
and/or thermocouple ports and will plug them.
• Pour a small amount of water into the cylinder on top of the cement--just enough to reach
the water fill line on the Slurry Level Gauge.
• Make certain the sealing components are properly installed on the bottom plug. Apply a
liberal coating of high temperature grease on the o-ring and back-up ring.
• Screw the top plug in place. It is important that the plug be tightened so that it just
contacts the top of the cylinder. Further tightening after the plug has contacted the
cylinder will not cause more effective sealing and will cause plug removal difficulty, as
well as severe damage to the cylinder and end caps. A small amount of water should
come out of the pressure or thermocouple port when the top plug is in place. This is very
important in that it shows that all the air has been removed from the cylinder.
• Connect the top sensor cable to the connection labeled TOP TRANSDUCER left/right.
The transit time should be between 14.5 and 17.0 micro-sec/inch at the beginning of a test
with pressure on the cell.
• Coat the top and bottom transducer surface with the couplant gel supplied in the
accessory kit.
• Connect the thermocouple cable to the connector labeled “T/C.”
• Install the thermocouple into the remaining high-pressure port in the top plug of the test
cell until the fitting is finger tight.
• Slowly open the pressure valve left/right until water begins to come out the thermocouple
connection vent hole. Quickly tighten the thermocouple with a 5/8” open-end wrench. It
is recommended a rag or paper towel be placed near the thermocouple vent hole to collect

SECTION 2 – OPERATING INSTRUCTIONS 2-7
the vented water and prevent it from running down inside the instrument or into the sensor
cavity.
The test cell and instrument are now ready to begin a compressive strength test.
Running a Test
Pressure Control
This section describes how the Pump Regulator and Pressure Relief Valves work together for
automatic pressure control.
As the test cell is heated, the pressure will increase. When the pressure exceeds the control
pressure upper limit, the relief valve will open and pressure will be reduced. If the heating rate
is reduced, as during the temperature transition from a ramp to a soak profile, the pressure in
the test cell may begin to fall. If the pressure falls below the control pressure lower limit, the
pump will stroke and bring the pressure back within the established limits.
The pump and relief valve will have a “dead band” or hysteresis in their operation. If the relief
valve is set to relieve at 4000 psig, it may open at 4000 psig, but may not close until the
pressure falls to, for example, 3900 psig. This 100 psig differential between opening and
closing is called the “dead band” or hysteresis. As another example, the pump may be set to
begin pumping if the pressure falls to 3000 psig, but the pressure may reach, for example,
3100 psig before the pump stops. This 100 psig differential between the start pressure and the
stop pressure is also known as “dead band” or hysteresis. If the upper and lower set points
are set too close together, this “dead band” may overlap and cause the system to go into a
continuous oscillation where the pump tries to increase pressure and the relief valve releases
all the pressure the pump is able to build. T he solution to this problem is to decrease the
lower set point or raise the upper set point or both.
Starting the Test
1. Turn the POWER switch to the ON position
2. Open the PRESSURE valve left/right on the cylinder to be pressured.
3. Turn the PUMP switch to the ON position and rotate the PUMP REGULATOR valve
clockwise until the cylinder reaches the desired pressure set point. If the cylinder will not
reach the pressure set point, turn the PRESSURE RELIEF valve clockwise until the
cylinder develops the desired pressure.
4. Turn the PRESSURE RELIEF valve counterclockwise slowly until the test cell pressure
begins to drop slightly below the set point. Continue turning the regulator knob slowly
until the pressure in the test cell equals the upper limit of the desired test pressure.
5. Turn the HEATER switch to ON. (The heater and pump will not start until the program
start up is initiated through the controller.)

2-8 SECTION 2 – OPERATING INSTRUCTIONS
6. To begin the test, the Temperature Controller program must be started by pressing the
EZ1 button on the controller. The output “1” light should begin flashing indicating the
control output to the heater and or pump.
7. The COOLANT switch should be OFF
Note: Turn the coolant control switch to AUTO if an external chiller is used.
Ending the Test
1. Turn the HEATER switch to the OFF position.
2. To end the test, turn the HEATER switch to the OFF position.
3. Turn the Temperature Controller OFF by pressing the Advance button so that the
controller displays CM.1 and pressing the up or down arrow buttons to select OFF.
Note: Always leave the controller in the OFF mode with the HEATER switch turned
OFF when the thermocouple is not installed in the cylinder.
4. Turn the COOLANT switch left or right to the ON position to cool the test cell. Monitor
the test cell temperature using the Temperature Controller. Use the pump to maintain
pressure on the test cell until the cell is cool. When the temperature is below 200°F
(93°C) the pump switch may be turned to the OFF position and the PRESSURE
RELEASE valve opened. Failure to maintain pressure at temperatures above 212°F
(100°C) may cause water in the test cell to become steam.
5. Turn PRESSURE Left/Right valve to the OPEN position (counterclockwise).
6. If no other test is running, turn the MAIN POWER switch to the OFF position.
7. Close the PRESSURE RELEASE valve (clockwise). Failure to do so will result in water
leakage.
8. Remove the Quick Disconnect connector from the test cell.
9. Disconnect the sensor cable.
10. Remove the thermocouple or disconnect the cable.
11. Lift the test cell from the instrument assembly.
Cleaning the Test Cell
When the test cell has been cooled and removed from the instrument, it should be cleaned
according the following guidelines.
1. Place the test cell in a vise, top side up. Use the wrench flats and do not scratch or nick
the cylinder or plugs.
2. Remove the top plug and pour off any standing water on the cement sample.
3. Remove the cell from the vise and then replace the cell in the vise, top side down.

SECTION 2 – OPERATING INSTRUCTIONS 2-9
4. Unscrew and remove the bottom plug of the test cell.
5. Turn the cell over and tap the cement sample out of the test cell with a drift bar and a
hammer.
6. Clean the cement and grease from the top and bottom plugs and cylinder with soap and
water, or an appropriate solvent.
7. When all traces of cement have been removed, replace the O-rings. Grease the inner
surfaces of the test cell, including the seal, O-rings, and threads with a liberal coating.
The unit is now ready to run another test.

2-10 SECTION 2 – OPERATING INSTRUCTIONS
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