ATS PAV3 User manual

Pressure Aging Vessel
PAV3

Contents
Preface        4
Unpacking       4
Warranty       4
Aer-SaleSupport      4
Secon1:Introducon      5
Secon2:Safety       6
2.1ForOwners,Operators,&Maintenance  6
2.2SafetyInstrucons     7
2.3Warnings      7
2.4Cauons      8
Secon3:SystemOverview     9
3.1GeneralDescripon     9
3.2Specicaons      10
3.3EnvironmentalCondions    11
Secon4:UnpackingandInstallaon    12
4.1Unpacking      12
4.2Installaon      12
4.3PanHolderLeveling     12
4.4AirandPowerConnecons    13
Secon5:Operaon      16

Contents
Secon6:Vericaon      43
6.1VerifyingTemperature     43
6.2VerifyingPressure     44
Secon7:Troubleshoong     45
7.1TemperatureDoesNotRecovertoSetpoint  45
7.2TroubleshoongthePAVController   46
7.3ReaachingtheFlowAdjustValve   47
7.4UpdangtheSoware     49
Secon8:Maintenance      51
8.1PrevenveMaintenance    51
8.2ChangingFuses      51
8.3SpareParts      52
AppendixA:Warranty      54
RevisedJanuary2015

4
Preface
Unpacking
Retainallcartonsandpackingmaterialsunltheunitisoperated
andfoundtobeingoodcondion.Ifdamagehasoccurred
duringshipping,nofyAppliedTestSystems(ATS)andthecarrier
immediately.Ifitisnecessarytoleadamageclaim,retainthe
packingmaterialsforinspeconbythecarrier.
Warranty
AllnewATSsystemsareshippedwithawarranty.Unitshavea
warrantyagainstdefecvepartsandworkmanshipforonefullyear
fromdateofshipment.PleaseseeAppendixA ofthismanualfor
completedetailsonthewarranty.
NOTE:Pleaseseethewarrantyinformaonincludedwiththe
computer.Itdetailsinformaonthatwillensurepropertransferof
thecomputerwarrantyfromATStotheappropriatecompany.
Aer-Sale Support
Ifthereareanyquesonsconcerningtheoperaonoftheunitor
soware,contacttheATSServiceDepartmentat[phone].
Beforecalling,pleaseobtainthesowarerevisionnumberandthe
serialnumberfromtheunit’sdatatag.Asampledatatagisshown
belowandcanbecompletedwiththeunit’sinformaonforeasy
reference.Pleasebepreparedtogiveacompletedescriponofthe
problemtoATSServiceEngineers.

5
Secon1:Introducon
TheAppliedTestSystems(ATS)PressureAgingVessel(PAV)
simulatesin-serviceoxidaveagingofasphaltbinderaccordingto
proceduresdevelopedbytheStrategicHighwayResearchProgram
(SHRP).ThePAVsystemisfullycompliantwiththemostrecent
versionsofASTMstandardD6521andAASHTOstandardmethod
R28.
Thisinformaonisrelatedtothefuncon,setup,safeoperaon,
andmaintenanceofthePAVanditsrelatedcomponents.
Thismanualisintendedforanyonewhowillbesengupand/or
operangthePAV.

6
Secon2:Safety
AllATSequipmentisdesignedtobeoperatedwiththehighestlevel
ofsafety.ThismanualandATSendeavortoeducatetheoperator
aboutsafetyissuessurroundingcertainpartsofthemachineryby
usingequipmentlabeling.
2.1 For Owners, Operators, and Maintenance
Personnel
Readandunderstandallinstruconsandsafetyprecauonslisted
inthismanualbeforeinstallingoroperangtheunit.Ifthereare
anyquesonsregardingoperaonoftheunitortheinstruconsin
thismanual,contacttheATSServiceDepartmentat+1-724-283-
1212.
Inaddiontothesafetywarningslistedontheequipment,
warningsarepostedthroughoutthismanual.Readandfollow
theseimportantinstrucons.Failuretoobservetheseinstrucons
canresultinpermanentdamagetotheunit,signicantproperty
damage,personalinjury,ordeath.
 ReadOperator’sManual
General Danger
 ProtecveEarth(Ground)
 BurnHazard(HotSurface)
 ElectricalShock/Electrocuon
 HandCrushForceFromAbove
 EuropeanDirecveCEMark
 NoAccessforUnauthorizedPersons

7
2.2 Safety Instrucons
1.Readandfollowallwarningandcauonstatementsinall 
relatedequipmentmanualsbeforeaempngtooperate 
thismachine.Ifindoubtaboutanystatementorsequence,
contactATSService.
2.Installaonofelectricaldevicesmustbeaccomplishedby 
competentpersonnelanddoneinaccordancewithany 
currentlocalandnaonalcodes.Equipmentgroundingisa
MUSTforbothsafetyandproperoperaon.
3.Beforesupplyingelectricalpowertotheunit,turnallpower
switchesandcontrolstoanOFForNEUTRALposion.
2.3 Warnings
Thefollowingstatementsarewarningstatements.Unlikecauon
statements,warningstatementsalerttheoperatortocondions
thatmayinjurepersonnel.Operatorsmustbeawareofthese
condionsinordertopreventinjuriesthatmayoccurwhile
operangthisequipment.
WARNING:Obeyelectricalcoderequirements.Theoven
andcontrolsystemmustbewiredandgroundedin
accordancewithnaonalandlocalelectricalcode 
 requirements.
WARNING:Becarefulwhenworkingwithequipmentat
elevatedtemperatures.Inordertopreventburns,wear
protecveclothing.
WARNING:Usecauonwhenopeningtheovenlid.
Electrically-heatedequipmentcancausesevereburns.
WARNING:Allowadequatemetorelieveallthe
pressurefromthevesselbeforeopeningtheovenlidand
thepressurevessellid.Anyunrelievedpressurecan 
 causeequipmentdamageandpossiblepersonalinjury.
WARNING:Unpackandoperateonastablesurface.

8
2.4 Cauons
Thefollowingstatementsarecauonstatements.These
statementsalerttheoperatortocondionsthatmaydamage
equipment.Operatorsmustbeawareofthesecondionsinorder
toensuresafeoperaonofthisequipment.
CAUTION:Installaonofelectricaldevicesmustbe
accomplishedbycompetentpersonnelanddonein
accordancewithanycurrentlocalandnaonalcodes.
CAUTION:ThePAVmustbegroundedandwiredin
accordancewithnaonalandlocalelectricalcode
requirements.
CAUTION:Beforeenergizingtheelectricalpowertothe
PressureAgingVessel,placeallcontrolsinanOFF
posion.
CAUTION:Donotexceedthemaximumoperang
temperature.RefertothespecicaonsinSecon3of
thismanual.
CAUTION:ClosingtheowadjustvalvewhenthePAVis
inoperaonwillcausedamagetothevalve.
CAUTION:Allsupporngandcontacngsurfacesmustbe
non-ammable.Donotallowammablematerialsto
contacttheshell.
CAUTION:Ifanemergencyshutdownneedstobe
performed,placeON/OFFswitchinanOFFposion.Unit
willdepressurizeautomacallywithin10-15minutes.
CAUTION:DonotoverowPAVpans.Refertotest
specicaonsforproperamountofmaterial.

9
Secon3:SystemOverview
3.1 General Descripon
TheATSPressureAgingVessel(PAV)isdesignedspecicallyto
preparespecimensfortestsdevelopedbytheStrategicHighway
ResearchProgram(SHRP)tosimulatein-serviceoxidaveaging
thatoccursinasphaltbindersduringservice.
APAVsystemconsistsofthefollowing:ASME/CEcodestainless
steelpressurevesselenclosedinastainlesssteeloven,pressure
regulator,meteringvalve,pressuretransducerandindicator,RTD,
temperaturecontrollerwithdatalogging,andpanholder.
3.1.1 Vessel Cercaon
ASMECode:Unlessotherwisenoted,thePressureAgingVessel
(PAV)isdesigned,fabricated,inspected,tested,andstampedin
accordancewiththeASME Boiler and Pressure Code,SeconVIII,
Divison1,forserviceatamaximumpressureof2.45MPa/350psig
andamaximumtemperatureof150°C/300°F.The ASME Boiler
and Pressure Vessel CodeisanInternaonallyRecognized
Standard.
ContactATSforthevesselcercate/U-IAReportandCE
DeclaraonofConformity.

10
3.2 Specicaons
BenchtopUnit IntegralVessel/OvenDesign
VercalLoadingwithFixture
SpecimenCapacity 10Pans
SpecimenPans  PerAASHTOT179
PhysicalDimensions 30”high,18”deep,27½”wide
(760mmhigh,460mmdeep,700mmwide)
Weight  290lbs(130kg)
OperangPressure 304.5psi(2.1±0.05MPa)
TemperatureAccuracy Setpoint±0.5°C
TemperatureRange 80°Cto115°C
RTDTemperatureMeasurement 0.1°CResoluonand±0.1°Accuracy
MicroprocessorTemperatureControl
OvertemperatureProtecon
PowerRequirements
ASMEOvenHighLimitSwitch293°F
(145°C)
240VAC,10amps,50/60Hz
VesselPerASMECodeSeconVIII Division1;1992A93ContactATS
VesselDesignCondions
PressureSafetyReleaseValve
TemperatureUniformity 
PressureDisplayAccuracy
“TIME”TimerAccuracy 
withthePAV’sserialnumberfora
copyofthecertification.
325psig(2.24MPa)at250°F(121°C)
340 psi
±0.5°C
±1%
0.1%
“OUTOFRANGE”TimerAccuracy 0.1%

11
AirInlet    Male¼”NPTFing
SolenoidValve   Closedwhenpowerisapplied.In
    theeventofpowerloss,solenoid
    valvewillopenandrelease 
    anypressureinthePAVvessel.
3.3 Environmental Condions
OperaonoftheATSPressureAgingVesselinvolvesuseofhigh
temperaturesandcontentsbeingcontainedathighpressure.
ThelocaonandplacementofthePAVshouldalwaystakethese
elementsintoconsideraontoensureasafeworkingenvironment.
ThePAVismeantforuseinlaboratory/factorysengsinadryand
cleanworkenvironment.TheworksurfacethatthePAVisplaced
onshouldbeacleanandsturdyworksurfaceatareasonable
workingheightandawayfromanywater,gas,orelectricalhazards.
Theworksurfaceshouldbeabletosupportmorethantheweight
oftheunititself.TheindoorareathePAVisplacedinshouldbe
wellvenlatedandcontainingnoopenamesormaterialsthat
mayconstutearehazard.

12
Secon4:UnpackingandInstallaon
4.1 Unpacking
Carefullyunpacktheequipmentandinspectitfordamageduring
shipment.Retainallcartonsandpackagingmaterialsunlthe
unitisoperatedandfoundtobeingoodcondion.Ifdamagehas
occurredduringshipping,nofythecarrierandATSimmediately.If
itisnecessarytoleadamageclaim,retainthepackingmaterials
forinspeconbythecarrier.
4.2 Installaon
1.UseanoverheadcraneorforklitoremovethePAVfromthe
crateandposionitinthedesiredlocaon.
2.PosionthePAVinthetesngposion,suchasonthePAV
heavy-dutysteelstandoronaworkbenchorlicart.
CAUTION:Allsupporngandcontacngsurfacesmust
benonammable.Donotallowammablematerialsto
contacttheshell.
3.LevelthePAVbyadjusngthescrewsonthefourfeet.
4.InspecttheO-ringseal.Makesureitiscleanandlightlycoated
withsiliconegrease.IftheO-ringappearstobewornordamaged,
contactATS.
4.3 Pan Holder Leveling
1.OncethePAVisinplace,verifythattheringlocatedinsidethe
boomofthepressurevesselislevelbyplacingtheparallelbar
andalevelacrossthetopofthelevelingring.
WARNING:Whenplacingthelevelandtheparallelbar
ontothering,donotinterferewiththeRTDlocatedin
theboomofthepressurevessel.TheRTDisfactory-set
 andshouldnotbemoved.
2.Ifthelevelindicatesthattheringisnotevenlybalanced,make
thenecessarycorreconsbyrotangthethreevercal-setscrews
tolowerorraisethering.Usea1/8”hexwrenchtomakethis
adjustment.

13
3.Aerlevelingthering,handrotatethehorizontal-setscrewsin
ordertosecuretheringintheboomofthevessel.
4.4 Air and Power Connecons
1.Installtheairpressurelinetothe1/4”malepipe-threadedng
providedonthebackofthecontrolcabinet.
CAUTION:Usearegulatedairsupplyof340to350psi
(2.34to2.41MPa).Donotexceed350psi(2.41MPa)or
thePAV’sperformancemaybeimpairedbyexcessive 
pressure.
2.Aconnectorisprovidedwiththeunit.Thisconnectormay
bechangedifitdoesnotmatchtheavailablereceptacle.Power
requirementsare:230-240VAC,±5V,10amp,single-phase,50/60
Hz.
CAUTION:ThePAVrequiresaminimumof230VACto
operatecorrectly.Checkthesupplyvoltagetoensureitis
230-240VAC.Ifthesupplyvoltageislessthan  
230VAC,aStep-UporBuck-Boosttransformercanbe 
 suppliedtoprovidetheproperoperangvoltages. 
 ContactATS.BepreparedtoprovidetheATSService 
 representavewithinformaonabouttheavailableAC
voltagesothecorrecttransformerwiringconguraon
 canbeprovided.
CAUTION:ThePAVandcontrolsystemmustbegrounded
accordingtonaonalandlocalcoderequirements.

14
3.Ifequipped,connecttheoponalUPSbaerybackupsupply.
 a.UsethesuppliedstandardpowercordtoplugtheUPS
 intothewall.Thesystemshouldchargefor24hours 
 beforeconnecngittothePAV.
 b.AachthesuppliedcordfromtheUPStothePAV.
 c.Seemanufacturer’sliteratureforfurthersetup 
 instrucons.
4.ChecktheowadjustvalveonthePAV(markedFlowControl)
toensureitissetatthecorrectvalues.Thisvalvecontrolstherate
atwhichthePAVdepressurizes.Whentheowadjustvalveisset
attherecommendedseng,thePAVwilldepressurizeatopmal
rate.Theunitwillhaveascker(seebelow)withthecorrect
values.UsethevaluemarkedFlowAdj.
NOTE:SeeSecon7forinformaononwhattodoiftheow
adjustvalvedetaches.

15
4.4.1 Regulator Connecons
1.Securetheairconnecontotheairtankusingthesuppliedmale
andfemaleconnecons.
2.Connectthehosetotheregulator.
NOTE:DoNOTconnectthehosetothepartmarkedFLOW.Thisis
thepressurereliefvalve,andnothingshouldbeconnectedtoit.
NOTE:OutsideoftheUnitedStates,adierentadaptermaybe
required.ACGAadapterisincluded.
3.AachthehosetothePAVusingthequickconnecons.Connect
themaleendofthehosetothefemaleconnecononthePAVby
slidingthefemaleconnecontowardsthePAV,connecngthe
hose,andreleasingtheslide.
4.Verifythatallconneconsareghtlysealedbyapplyingsoapy
waterontheconneconsandturningontheair.Ifsudsappear,
applymorecompoundortapetosealtheleak.

16
Secon5:Operaon
PoweronthePAVbyturningtheMainPowerswitch1.
locatedonthefrontofthePAVclockwisetothe“ON”
posion.
NOTE:Makesuretheairisconnectedandsetat340-350psias
describedinSecon4.4.

17
Soware/SengupUserLanguage2.
Select“View.”ThiswilldisplaytheInformaona.
screen.ThecurrentversionofthePAVsoware
willdisplay.

18
b. ThePAVwilldisplayitemsinEnglishasthedefault
language.TochangethelanguagefromEnglishto
oneofthepreprogrammedlanguages,accessthe
oponsfromthetouch-screendisplay.
Select“View”i.
Select“Language”ii.
Touchthedesiredlanguageforthedisplay.iii.
c. Select“Done”toreturntothepreheatstartup
screen.

19
SengupaBasicTest3.
Temperaturea.
Setthechambersetpointbytouchingthei.
greenboxabove“ChamberSetpoint.”
Enterthesetpointtemperatureintheii.
keypadthatpopsup.
Temperaturerangesare1.
programmablefrom50⁰C-150⁰
C;however,onlytemperatures
between80⁰C-115⁰Care
calibratedtobewithin±0.5⁰Cof
thesetpoint.

20
DoNOTenterasetpoint2.
temperaturehigherthanthe
actualtemperaturevaluewhich
willbeusedfortheAging
Procedure.ThePAVisdesignedto
operatemostecientlywhenthe
PressureVesselandSampleRack
arepreheatedtothetemperature
atwhichAgingwillbedone.
NOTE:Aempngtopreheatthe
PressureVesseland/orSample
Racktoahighertemperaturethan
theAgingproceduretemperature
mayresultineitheralonger
periodofmerequiredforthe
PAVtorecovertemperature
aerPressureisappliedand/or
apoorercontrolofthechamber
temperatureaerpressureis
appliedtothechamber.
Whennished,touch“ENT.”iii.