ATS Pressure Aging Vessel 4 User manual

MAN - PAV4 - REV: Original
PAV4
Pressure Aging Vessel 4
INSTRUCTION MANUAL
This manual contains important operating and safety information. Carefully read and understand the
contents of this manual prior to the operation of this equipment.
www.atspa.com

MAN - PAV4 - REV: Original
REVISED AUGUST 2019
Information in this document is subject to change without notice and does not represent a commitment on the part of:
Applied Test Systems (ATS)
154 East Brook Lane
Butler, PA 16002
USA
Telephone: [phone]
For assistance with set-up or operation, contact the ATS service department. Please have this manual and product
serial number available when you call.
© Copyright Applied Test Systems 2019

MAN - PAV4 - REV: Originali
Manual Contents
A. Introduction......................................................................................................... 1
A.1 Unpacking ....................................................................................................... 1
A.2 Warranty Information........................................................................................ 1
A.3 After Sale Support............................................................................................ 1
B. Safety................................................................................................................... 2
B.1 For Owners, Operators, and Maintenance............................................................. 2
B.2 Safety Instructions ........................................................................................... 2
B.3 Warnings......................................................................................................... 3
B.4 Cautions ......................................................................................................... 3
C. System Overview.................................................................................................. 5
C.1 General Description .......................................................................................... 5
C.2 Vessel Certication ........................................................................................... 5
C.3 Specications .................................................................................................. 5
C.4 Environmental Conditions .................................................................................. 6
D. Installation .......................................................................................................... 7
D.1 Unpacking ....................................................................................................... 7
D.2 Installation...................................................................................................... 7
D.3 Pan Holder Leveling .......................................................................................... 7
D.4 Air and Power Connections ................................................................................ 8
D.5 Regulator Connections ...................................................................................... 9
E. Software Overview ............................................................................................. 11
E.1 Software Screen Map ...................................................................................... 11
E.2 Main Screen................................................................................................... 11
Preheat Button ........................................................................................... 12
Age Cycle Button ........................................................................................ 12
End/Stop Button ......................................................................................... 12
Shut O Button .......................................................................................... 12
View Button ............................................................................................... 13
O State.................................................................................................... 13
Preheat State ............................................................................................. 14

MAN - PAV4 - REV: Original ii
Load Samples State .................................................................................... 14
Recovery / Pressurizing State ....................................................................... 14
Aging Cycle State........................................................................................ 14
Aging Finished State.................................................................................... 15
Preheat Delay State .................................................................................... 15
Data Button ............................................................................................... 16
Graph Button.............................................................................................. 16
Done Button............................................................................................... 16
E.3 View Screen................................................................................................... 16
IP Address ................................................................................................. 17
ID............................................................................................................. 17
Password ................................................................................................... 17
Standardize Button ..................................................................................... 17
Passwords Button........................................................................................ 17
Settings, Language, Data, and Alarm Buttons ................................................. 17
Done Button............................................................................................... 17
E.4 Language Screen............................................................................................ 17
E.5 Settings Screen.............................................................................................. 18
Pressure Temp Window ................................................................................ 18
Age Time ................................................................................................... 19
Age Temp .................................................................................................. 19
Age Pressure .............................................................................................. 19
Pressure Alarm Time ................................................................................... 19
Recovery Limit............................................................................................ 19
Age Limit ................................................................................................... 19
Temperature Drop-Down Field ...................................................................... 19
Pressure Drop-Down Field ............................................................................ 19
Shuto Heater at End of Test Checkbox ......................................................... 19
Stop Test on all Errors Checkbox ................................................................... 20
Current Time.............................................................................................. 20
Preheat Delay............................................................................................. 20
Done Button............................................................................................... 20
E.6 Alarm Screen ................................................................................................. 20
Alarm O Button......................................................................................... 20
Done Button............................................................................................... 20
E.7 Data Screen................................................................................................... 21

MAN - PAV4 - REV: Originaliii
Backup All to USB ....................................................................................... 21
Done Button............................................................................................... 21
Graph Button.............................................................................................. 21
F. Operation ........................................................................................................... 23
G. Verication ........................................................................................................ 26
G.1 Verifying Temperature..................................................................................... 26
G.2 Verifying Pressure .......................................................................................... 27
H. Troubleshooting ................................................................................................. 28
H.1 Temperature Does Not Recover to Setpoint ........................................................ 28
H.2 Troubleshooting the PAV Controller ................................................................... 28
H.3 Reattaching the Flow Adjust Valve .................................................................... 29
H.4 New HMI Software.......................................................................................... 30
H.5 New PLC Software .......................................................................................... 32
H.6 New Temperature Controller Software ............................................................... 32
I. Maintenance ....................................................................................................... 33
I.1 Preventative Maintenance................................................................................. 33
I.2 Changing Fuses .............................................................................................. 33
I.3 Spare Parts .................................................................................................... 33
Consumables.............................................................................................. 33
Accessories ................................................................................................ 34
Spare Parts ................................................................................................ 35
Appendix A: Warranty ............................................................................................ 36
Appendix B: Image Glossary .................................................................................. 37

MAN - PAV4 - REV: Original | A. Introduction1
A. Introduction
A.1 Unpacking
Retain all cartons and packing materials until the unit is operated and found to be in good condition. If damage has
occurred during shipping, notify Applied Test Systems (ATS) and the carrier immediately. If it is necessary to le a
damage claim, retain the packing materials for inspection by the carrier.
A.2 Warranty Information
All new ATS systems are shipped with a warranty. Units have a warranty against defective parts and workmanship for
one full year from the date of shipment. Please see APPENDIX A of this manual for complete details on the warranty.
A.3 After Sale Support
If there are any questions concerning the operation of the unit or software, contact the ATS Service Department at
[phone].
Before calling, please obtain the software revision number from the View Screen and the serial number from the
unit’s data tag. A sample data tag is illustrated below, and can be completed with the unit’s information for easy
reference. Please be prepared to give a complete description of the problem to the ATS Service Department.
Figure A.1: ATS Sample Data Tag

MAN - PAV4 - REV: Original | B. Safety 2
B. 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.
B.1 For Owners, Operators, and Maintenance
Read and understand all instructions and safety precautions listed in this manual before installing or operating the
unit. If there are any questions regarding operation of the unit or the instructions in this manual, contact the ATS
Service Department at [phone].
In addition to the safety warnings listed on the equipment, warnings are posted throughout this manual. Read and
follow these important instructions. Failure to observe these instructions can result in permanent damage to the unit,
signicant property damage, personal injury, or death.
Read Operators Manual
General Danger
Protective Earth (Ground)
Burn Hazard (Hot Surface)
Electrical Shock/Electrocution
Hand Crush Force from Above
European Directive CE Mark
No Access for Unauthorized Persons
B.2 Safety Instructions
1. Read and follow all warnings and caution statements in all related equipment manuals before attempting to operate
this machine. If in doubt about any statement or sequence, contact the ATS Service Department.

MAN - PAV4 - REV: Original | B. Safety3
2. Installation of electrical devices must be accomplished by competent personnel and done in accordance with any
current local and national codes. Equipment grounding is a MUST for both safety and proper operation.
3. Before supplying electrical power to the unit, turn all power switches and controls to an OFF or NEUTRAL position.
B.3 Warnings
The following statements are WARNING statements. Unlike CAUTION statements, WARNING statements alert the
operator to conditions that may injure personnel. Operators must be aware of these conditions in order to prevent
injuries that may occur while operating this equipment.
WARNING: Obey electrical code requirements. The oven and control system must be wired and
grounded in accordance with national and local electrical code requirements.
WARNING: Be careful when working with equipment at elevated temperatures. In order to prevent
burns, wear protective clothing.
WARNING: Use caution when opening the oven lid. Electrically heated equipment can cause
severe burns.
WARNING: Allow adequate time 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.
B.4 Cautions
The following statements are CAUTION statements. These statements alert the operator to conditions that may
damage equipment. Operators must be aware of these conditions in order to ensure safe operation of this equipment.
CAUTION: Installation of electrical devices must be accomplished by competent personnel and
done in accordance with any current local and national codes.
CAUTION: The PAV must be grounded and wired in accordance with national and local electrical
code requirements.

MAN - PAV4 - REV: Original | B. Safety 4
CAUTION: Before energizing the electrical power to the Pressure Aging Vessel, place all controls
in an OFF position.
CAUTION: Do not exceed the maximum operating temperature. Refer to the specications in
Section C of this manual.
CAUTION: Closing the ow adjust valve when the PAV is in operation will cause damage to the
valve.
CAUTION: All supporting and contacting 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
position. Unit will depressurize automatically within 10-15 minutes.
CAUTION: Do not overow PAV pans. Refer to test specications for proper amount of material.

MAN - PAV4 - REV: Original | C. System Overview5
C. System Overview
C.1 General Description
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 oxidative 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 black powder
coated steel enclosure, pressure regulator, metering valve, pressure transducer and indicator, RTD, temperature
controller with data logging, and pan holder.
C.2 Vessel Certication
ASME Code: Unless otherwise noted, the PAV is designed, fabricated, inspected, tested, and stamped in accordance
with the ASME Boiler and Pressure Code, Section VIII, and a maximum temperature of 110°C/121°C. The ASME
Boiler and Pressure Vessel Code is an Internationally Recognized Standard.
Contact ATS for the vessel certicate/U-IA Report and CE Declaration of Conformity.
C.3 Specications
Benchtop Unit Integral Vessel/Oven Design
Vertical Loading with Fixture
Specimen Capacity 10 Pans
Specimen Pans Per AASHTO T 179
Physical Dimensions 30” high, 22” deep, 27” wide
(760mm high, 558.8 mm deep, 685.8 mm wide)
Weight 300 lbs (136.078 kg)
Operating Pressure 304.5 psi (2.1± 0.05 MPa)
Temperature Accuracy Setpoint ± 0.5°C
Temperature Range 80°C to 110°C/121°C

MAN - PAV4 - REV: Original | C. System Overview 6
RTD Temperature
Measurement
0.1°C Resolution and ± 0.1° accuracy Microprocessor Temperature
Control with overlimit protection
Power Requirements 230/240 VAC, 10 amps, 50/60 HZ
Vessel Per ASME Code
Section VIII
Division 1; 1992 A 93 Contact ATS with the PAV’s serial number for
a copy of the certication
Vessel Design
Conditions
325 psig (2.24 MPa) at 110°C/121°C
Pressure Safety
Release Valve
340 psi
Temperature Uniformity ± 0.5°C
Pressure Display
Accuracy
±1%
“TIME” Timer Accuracy 0.1%
“OUT OF RANGE”
Timer Accuracy
0.1%
Air Inlet Male 1/4” NPT Fitting
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.
C.4 Environmental Conditions
Operation of the ATS Pressure Aging Vessel involves use of high temperatures and contents being contained at
high pressure. The location and placement of the PAV should always take these elements into consideration to
ensure a safe working environment. The PAV is meant for use in laboratory/factory settings 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 that the PAV is placed in should be well ventilated and containing no
open ames or materials that may constitute a re hazard.

MAN - PAV4 - REV: Original | D. Installation7
D. Installation
D.1 Unpacking
Carefully unpack the equipment and inspect it for damage during shipment. Retain all cartons and packing materials
until the unit is operated and found to be in good condition. If damage has occurred during shipping, notify the carrier
and ATS immediately. If it is necessary to le a damage claim, retain the packaging materials for inspection by the
carrier.
D.2 Installation
1. Use an overhead crane or forklift to remove the PAV from the crate and position it in the desired location.
2. Position the PAV in the testing position, such as on the PAV heavy-duty steel stand or on a workbench or lift cart.
CAUTION: All supporting and contacting surfaces must be nonammable. Do not allow
ammable materials to contact the shell.
3. Level the PAV by adjusting 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.
D.3 Pan Holder Leveling
1. Once the PAV is in place, you will need to verify that the leveling ring is evenly balanced. The leveling ring is
removed prior to shipment, and needs to be checked on a level surface with a level, prior to placing it back in the
vessel.
WARNING: When placing the level and the parallel bar onto the ring, do not interfere with the
RTD located in the bottom 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 corrections by rotating the three
vertical-set screws to lower or raise the ring. use a 1/8” hex wrench to make this adjustment.
3. After leveling the ring, hand rotate the horizontal-set screws in order to secure the ring in the bottom of the vessel.

MAN - PAV4 - REV: Original | D. Installation 8
D.4 Air and Power Connections
1. Install the air pressure line to the 1/4” male pipe-threaded tting 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 operating voltages. Contact ATS.
Be prepared to provide the ATS Service representative with information about the available AC
voltage so the correct transformer wiring conguration can be provided.
CAUTION: The PAV and control system must be grounded according to national and local code
requirements.
Figure D.1: Pan Holder Leveling
Figure D.2: Power connector

MAN - PAV4 - REV: Original | D. Installation9
3. If equipped, connect the optional UPS battery backup supply.
a. Use the supplied standard power cord to plug the UPS into the wall. The system should charge for 24
hours before connecting it to the PAV.
b. Attach the supplied cord from the UPS to the PAV.
c. See manufacturer’s literature for further setup instructions.
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 setting, the
PAV will depressurize at optimal rate. The unit will have a sticker (see below) with the correct values. Use the value
marked Flow Adj.
NOTE: See Section I.Maintenance for information on what to do if the ow adjust valve detaches.
D.5 Regulator Connections
1. Secure the air connection to the air tank using the supplied male and female connections.
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.
Figure D.3: Sticker with values Figure D.4: Flow Control valve

MAN - PAV4 - REV: Original | D. Installation 10
NOTE: Outside of the United States, a different adapter may be required. A CGA adapter is
included.
3. Attach the hose to the PAV using the quick connections. Connect the male end of the hose to the female
connection on the PAV by sliding the female connection towards the PAV, connecting the hose, and releasing the
slide.
4. Verify that all connections are tightly sealed by applying soapy water on the connections and turning on the air. If
suds appear, apply more compound or tape to seal the leak.
Figures D.5 - D.7: Regulator Connections

MAN - PAV4 - REV: Original | E. Software Overview11
E. Software Overview
E.1 Software Screen Map
Figure E.1 shows the PAV’s software screens.
E.2 Main Screen
Figure E.2 below shows the Main Screen, which displays when the PAV is started. It allows you to setup and run age
Figure E.1: PAV Software Screen Map

MAN - PAV4 - REV: Original | E. Software Overview 12
The screen will show values for current chamber temperature and pressure, chamber set point, remaining cycle time,
and error times. It also has several controls to set-up and run the pressure aging vessel (PAV).
Preheat Button
Used to heat the PAV up to operating temperature before loading samples into the vessel.
Age Cycle Button
Used to tell the system that parts are loaded, to start the recovery for the age cycle.
End/Stop Button
Used to tell the system to nish the cycle. It can also be used anytime the PAV is in cycle to stop the age cycle. When
the age cycle has nished this button will blink to show the cycle is nished. If pressed while in an aging cycle a pop-
up dialog will ask if you are sure you wish to end the current test.
Shut Off Button
Can be used at any time to shut down the PAV. This will stop all cycles, shut off heat, and reset the system to the off
state. If pressed a pop-up dialog will ask if you are sure you wish to end the current test.
Figure E.2: PAV Main Screen

MAN - PAV4 - REV: Original | E. Software Overview13
View Button
Used to get to all other screens in the system for Set-up. This button will be replaced with a Graph Button when an
age cycle is running. See sections below referencing the Graph and Data screens for more information.
Below is what the main screen looks like when the system is in aging cycle state. Note the “Remaining Time” being
displayed. This will show up for the Preheat Delay and the Aging Cycle states and will display the time remaining for
this part of the cycle.
Near the top of the display is a status bar that will show the current state of the oven cycle. Below are the different
states in the order that they usually run.
Off State
Displayed when the system is sitting idle. No heat or cycle is running.
Figure E.3: PAV Main Screen - Aging Cycle
Figure E.4: Off State

MAN - PAV4 - REV: Original | E. Software Overview 14
Preheat State
Displayed when the chamber is heating up. The system will stay here until the chamber is at temperature and stable
Load Samples State
Displayed when the chamber is stable at temperature The system will stay here until the Age Cycle button is pressed.
Recovery / Pressurizing State
Displays when the Age Cycle button has been pressed. The system will recover to the cycle temperature. When it
gets within the pressuere temperature window it will start to pressurize. It will stay in this state until the vessel is at
cycle temperature and pressure.
Aging Cycle State
Displays when the vessel is at cycle temperature and pressure, the age cycle starts. It will stay in this state holding
temperature and pressure until the age cycle has timed out.
Figure E.5: Preheat State
Figure E.6: Load Samples State
Figure E.7: Recovery / Pressurizing State
Figure E.8: Aging Cycle State

MAN - PAV4 - REV: Original | E. Software Overview15
Aging Finished State
Displays when the age cycle has timed out and the system is waiting for the operator to press the “End” button and
remove the parts.
Caution should be used as the parts are still very hot.
Preheat Delay State
Displays when the system has been set up to start the preheat automatically after a time delay. You can think of this
like a “coffee timer”.
Below are the Graph and Data screens that are available when you press the Graph button on the Main Screen. It
allows you to view the graph and data of the currently running age cycle.
Figure E.9: Aging Finished State
Figure E.10: Preheat Delay State
Figure E.11: Graph Screen Figure E.12: Data Screen