Troxler ICO 4740 User manual

Manual of Operation and Instruction
Troxler ICO™
NCAT Oven
(Model 4740)
Troxler Electronic Laboratories, Inc.
3008 Cornwallis Rd. •P.O. Box 12057
Research Triangle Park, NC 27709
Phone: 1.877.TROXLER
Outside the USA: +1.919.549.8661
Fax: [phone]
www.troxlerlabs.com

ICO i
Troxler products are protected by US and foreign patents.
Copyright 2013-2019
Troxler Electronic Laboratories, Inc.
All Rights Reserved
No part of this manual may be reproduced or transmitted in any
form or by any means, electronic or mechanical, including
photocopying, recording, or information storage and retrieval
systems, for any purpose without the express written
permission of Troxler Electronic Laboratories, Inc.
Superpave is a trademark of the Strategic Highway Research
Program.
UM4740 PN121600
September 2019
Edition 1.4

ii
TROXLER SERVICE CENTERS
Troxler Corporate Headquarters
P.O. Box 12057
Research Triangle Park, NC 27709
Phone: 1.877.TROXLER (1.877.876.9537)
Outside the U.S.A.: +1.919.549.8661
Fax: [phone]
Technical Support
Phone: 1.877.TROXLER
(1.877.876.9537)
[e-mail]
North Carolina Service Center
3008 E. Cornwallis Road
Research Triangle Park, NC 27709
Phone: [phone]
Fax: [phone]
[e-mail]
Florida Office & Service Center
2376 Forsyth Road
Orlando, FL 32807
Phone: [phone]
Fax: [phone]
[e-mail]
Midwestern Office & Service Center
1430 Brook Drive
Downers Grove, IL 60515
Phone: [phone]
Fax: [phone]
[e-mail]
Western Office & Service Center
11300 Sanders Drive, Suite 7
Rancho Cordova, CA 95742
Phone: [phone]
Fax: [phone]
[e-mail]
Southwestern Office &
Service Center
2016 East Randol Mill Rd., Suite 406
Arlington, TX 76011
Phone: [phone]
Fax: [phone]
[e-mail]
Troxler Europe & Service Center
Troxler Electronics GmbH
Waldstrasse 4, D.82239 Alling nr.
Munich, Germany
Phone: ++ 49.8141.71063
Fax: ++49.8141.80731
[e-mail]
Troxler Electronic Technologies
(Zhangjiagang)
1F, Bldg G, No. 1 Guotai North Road
ZJG, China, 215600
Phone: [phone]
Fax: [phone]
[e-mail]
To locate an independent, Troxler-authorized service partner near
you, call 1.877.TROXLER (1.877.876.9537).

ICO iii
ABOUT THIS MANUAL
The Troxler ICO NCAT Oven (Model 4740) Manual of
Operation and Instruction provides detailed information
about the oven. The manual includes product safety
information, as well as instructions for selecting an
installation site, installing the oven, and using the oven to
burn hot-mix asphalt (HMA) samples and to store sample
data.
This manual is organized as follows:
Chapter 1, Introduction to the ICO – Provides a brief
overview of the oven and its features, as well as a list of
parts and accessories, and instructions for unpacking and
inspection.
Chapter 2, Product Safety Information – Includes
information on the safe use of the oven.
Chapter 3, Installation – Contains instructions for
installing the oven, including the criteria for selecting an
installation site.
Chapter 4, Setup and Operation – Describes the oven
keypad, and provides instructions for setting up, starting,
operating, and shutting down the oven.
Chapter 5, Main Menu – Provides a detailed description
of the oven software, including examples and explanations
of the control menus.
Chapter 6, Calibration – Includes instructions for
determining correction factors, and for calibrating the
integrated scale.
Chapter 7, Handling Data – Contains instructions on
creating and using project files and describes how to view,
erase, print, and download data.

iv
Appendix A, Maintenance and Service – Provides
maintenance and service information, as well as
instructions on basic troubleshooting.
Appendix B, Menu Map – Shows a map of the menus in
the oven control software.
Appendix C, Specifications – Contains the
environmental, performance, electrical, and mechanical
specifications of the oven.

ICO v
HOW TO USE THIS MANUAL
Before using the ICO, read this manual carefully. Of
particular importance is the safety information in Chapter
2. Do not attempt to operate the oven before reading this
manual and the safety warnings posted on the unit.
Troxler stresses that the user is solely responsible for
ensuring the safe use of the oven. Neither the
manufacturer, its subsidiary, distributors, nor
representatives can assume responsibility for any
mishaps, damage, or personal injury that may occur from
failure to observe the safety warnings in this manual and
posted on the unit.
The oven allows measurement of the asphalt content of
asphalt mixes. After ignition testing, the remaining
aggregates may be used as sample for gradation
measurements. The Troxler ICO NCAT Oven (Model 4740)
Manual of Operation and Instruction describes the
installation, setup, and operation of the ICO.

vi
CONVENTIONS USED IN THIS MANUAL
Throughout this manual the following symbols and special
formatting are used to reveal the purpose of the text.
WARNING!
Warnings indicate conditions or procedures that, if
not followed correctly, may cause personal injury.
CAUTION
Cautions indicate conditions or procedures that, if not
followed correctly, may cause equipment damage.
NOTE
Notes indicate important information that must be
read to ensure proper operation.
〈KEY〉This style indicates a key or character to press on the
ADU keypad.
DISPLAY–Typestyle and
shading used to simulate
the control panel display
1. Indicates a procedure with multiple steps.
♦Indicates a list of items required (such as equipment) or
important points to know.
Indicates that more than one option is available. Carefully
select the option that applies.

ICO vii
TABLE OF CONTENTS
CHAPTER 1: INTRODUCTION TO THE ICO ...............1-1
INTRODUCTION.......................................................................................1-2
FEATURES...................................................................................................1-4
UNPACKING AND INSPECTING...........................................................1-9
CHAPTER 2: PRODUCT SAFETY INFORMATION........2-1
INTRODUCTION.......................................................................................2-2
CAUTIONS AND WARNINGS ...............................................................2-4
SAFETY WARNINGS ................................................................................2-6
CHAPTER 3: INSTALLATION......................................3-1
SITE SELECTION .......................................................................................3-2
EXHAUST SYSTEM INSTALLATION.....................................................3-5
INSTALLATION WITH AN EXHAUST HOOD ................................. 3-12
INSTALLATION WITHOUT AN EXHAUST HOOD ........................ 3-15
AIRFLOW LIFT ........................................................................................ 3-18
EXHAUST LEAKS.................................................................................... 3-22
CHAPTER 4: SETUP AND OPERATION ......................4-1
KEYPAD.......................................................................................................4-2
PRINTER......................................................................................................4-4
FIRST-TIME STARTUP AND SETUP......................................................4-5
DAILY STARTUP AND OPERATION ....................................................4-9
DAILY SHUTDOWN.............................................................................. 4-16
CHAPTER 5: MAIN MENU .........................................5-1

viii
OVEN MAIN MENU.................................................................................5-2
BURN SETUP MENU................................................................................5-4
AUTO-TIMER.......................................................................................... 5-16
PROJECT MENU .................................................................................... 5-21
CORRECTION MENU........................................................................... 5-22
SCALE MENU.......................................................................................... 5-23
STATUS MENU....................................................................................... 5-24
STORE FUNCTION................................................................................ 5-27
MISCELLANEOUS MENU .................................................................... 5-31
CHAPTER 6: CALIBRATION .......................................6-1
CORRECTING %AC MEASUREMENTS ...............................................6-2
CORRECTION MENU ..............................................................................6-8
SCALE MENU.......................................................................................... 6-12
CHAPTER 7: HANDLING DATA .................................7-1
PROJECTS...................................................................................................7-2
PROJECT MENU .......................................................................................7-3
APPENDIX A: MAINTENANCE AND SERVICE ............. A-1
TROUBLESHOOTING ............................................................................. A-2
CLEANING................................................................................................. A-5
REPLACING PARTS ................................................................................. A-8
RETURNING PARTS FOR SERVICE....................................................A-12
APPENDIX B: MENU MAP.......................................... B-1
MENU MAP DESCRIPTION....................................................................B-2

ICO ix
APPENDIX C: SPECIFICATIONS .................................. C-1
ENVIRONMENTAL CONDITIONS....................................................... C-2
PERFORMANCE SPECIFICATIONS ..................................................... C-3
ELECTRICAL SPECIFICATIONS............................................................. C-4
MECHANICAL SPECIFICATIONS......................................................... C-5
INDEX
WARRANTY

x
LIST OF FIGURES
Figure 1: Parts and Accessories ............................................................1-8
Figure 2: Basket Carrier ..........................................................................2-9
Figure 3: Overall Schematic for Exterior Wall and Roof
Penetrations...............................................................................................3-6
Figure 4: Exterior Wall Penetration Using a Metal Elbow and Cap
.......................................................................................................................3-6
Figure 5: Exterior Wall Penetration Using a Metal Wall Cap with
Screen..........................................................................................................3-7
Figure 6: Roof Penetration ....................................................................3-9
Figure 7: Exhausting to a Fume Hood............................................. 3-10
Figure 8: ICO Exhaust Pipe Below the Hood Intake Edge.........3-12
Figure 9: ICO Exhaust Pipe Extended into the Hood.................. 3-13
Figure 10: External Duct Cover (Open Design) ............................. 3-17
Figure 11: External Duct Cover (Closed Design)............................ 3-17
Figure 12: ICO Airflow ..........................................................................3-18
Figure 13: Exhaust Plenum Box and Louvers................................. 3-19
Figure 14: Oven Keypad .........................................................................4-2
Figure 15: Printer Front Panel ...............................................................4-4
Figure 16: Sample Basket Assembly.................................................4-12
Figure 17: Sample Reduced Printout................................................ 5-12
Figure 18: Sample Aggregate Correction Factor Form..................6-4
Figure 19: Opening Bottom Printer Door to Access Paper .........A-9
Figure 20: Opening Upper Printer Door to Access Paper.........A-10

ICO xi
Figure 21: Disengage Paper Spindle ................................................A-10
Figure 22: Insert New Paper Roll ......................................................A-11

ICO 1-1
Chapter 1:
INTRODUCTION TO
THE ICO
This chapter provides a brief overview of the ICO.
This information includes a list of the parts and
accessories, as well as instructions for unpacking
and inspecting the oven upon receipt.

1-2
INTRODUCTION
The two major components of HMA are the asphalt binder and
the aggregate. Thus, accurate measurements of the percent
asphalt content (%AC) and aggregate gradation are required for
HMA quality control and assurance. The ICO allows safe, quick,
and reliable measurement of the %AC of HMA samples and
creates samples for aggregate gradation measurements.
The oven employs a method developed by the National Center
for Asphalt Technology (NCAT) called pyrolysis, or ignition. In
this method, an HMA sample of known mass is prepared. The
asphalt binder in the sample is then burned. The change in
sample mass indicates the %AC. Standard sieve analysis of the
remaining clean aggregate provides the gradation.
The ignition oven test method is covered by the provisions of
ASTM D6307 (Standard Test Method for Asphalt Content of
Asphalt Mixture by Ignition Method) and AASHTO T 308
(Determining the Asphalt Binder Content of Hot Mix Asphalt
(HMA) by the Ignition Method).
The oven can also be used in conjunction with a nuclear asphalt
content gauge, such as Troxler Models 3241–D, 3241 USS, and
3242. The nuclear gauge provides a fast method of measuring
the %AC when the aggregate gradation is not needed. The oven
can be used when a job requires aggregate gradation.
The nuclear gauge test method is covered by the provisions of
the ASTM Standard D 4125, Standard Test Method for Asphalt
Content of Bituminous Mixtures by the Nuclear Method. For more
information on Troxler's asphalt content gauges, contact your
Troxler representative.

ICO 1-3
WARNING
Do not attempt to operate the oven before reading
this manual and the safety warnings posted on the
unit. Troxler stresses that the user is solely responsible
for ensuring the safe use of the oven. Neither the
manufacturer, its subsidiary, distributors, nor
representatives can assume responsibility for any
mishaps, damage, or personal injury which may occur
from failure to observe the safety warnings in Chapter
2 of this manual and posted on the unit.

1-4
FEATURES
The oven incorporates a number of features that provide
unparalleled efficiency, safety, usability, and flexibility.
The oven can be powered from a 208–240 V AC, 50/60 Hz, 30 A
source. The oven is therefore convenient for use in construction
trailers, where power sources may be limited.
Oven Door Lock
The oven door lock helps ensure operator safety. The oven
monitors the state of the door and will not apply electrical
power to the heating element if the door is open. The oven door
is locked automatically at the start of a burn cycle. The door
remains locked until five minutes have elapsed since the
chamber temperature has peaked or since the 〈ABORT〉key
was pressed.
Sample Basket
The sample basket assembly provides operator safety while
handling HMA samples, and to ensure an even burn of the
asphalt binder. A basket carrier is provided for lifting the
baskets in and out of the oven. A sample safety cage shields the
hot sample basket assembly while the asphalt sample cools.
Integrated Scale
The integrated scale continuously monitors the sample mass
loss during a burn cycle.
The oven features an Auto-Tare function that automatically
tares (zeroes) the integrated scale when no mass is present. The
oven software also enables the operator to tare the scale
manually, to calibrate the scale, and to verify the scale
calibration.

ICO 1-5
Oven Keypad and Internal Logic
The oven keypad and internal logic provide control, data
storage, and output flexibility. The keypad enables the operator
to set up and operate the oven, to store sample data, to calibrate
and verify the integrated scale, and to enter correction factors.
Auto-Timer
The oven includes an Auto-Timer function that can preheat the
oven automatically based upon start and stop dates and times
entered by the operator.
Audible Indicators
The oven features two audible indicators, an internally mounted
beeper and a louder annunciator mounted on the rear panel. The
beeper emits a short beep in response to a valid keystroke on
the oven keypad. It sounds a longer beep when the operator
presses an invalid key or the oven displays an error message.
The annunciator sounds when the door is unlocked at the
completion of a burn cycle. The red BURN COMPLETE
indicator on the front panel also lights when the door is
unlocked.
Internal Printer
The internal printer enables the operator to print sample data
and system status information, either automatically or
manually.
External Communications Ports
Two ports, a serial communications port and an auxiliary port,
are mounted on the rear panel of the oven. The serial
communications port, the leftmost of the two ports (as viewed
from the rear of the oven), is used to output data to a serial
device, such as a computer or printer. The auxiliary (right) port
is intended for factory use only.

1-6
Aggregate Correction Factors
The oven stores up to twenty user-defined aggregate correction
factors (ACFs), which are percentage values used to adjust the
measured asphalt content for specific aggregates.
Measurement Displays
During a burn cycle, the oven displays measurement units of
percent loss (%Loss). The %Loss measurement is the difference
between the sample weights before and after the burn cycle,
expressed as a percentage of the starting mass.
Two Burn Modes
The oven offers two burn modes. The burn time can be set
manually by the operator (Program Time mode), or it can be
adjusted automatically by the oven (Auto-Control mode). In
Auto-Control mode, the oven limits the burn time according to
the cutoff limit specified by the operator. The cutoff limit can be
defined in grams or as a percentage.
The oven can store data for up to 200 HMA samples. Sample
data is stored in project files created by the operator. Up to
twenty project files can be defined. Sample data is stored in the
active project file, either manually using identification numbers
entered by the operator, or automatically using the Auto-Store
function.
PARTS AND ACCESSORIES
Figure 1 shows the ICO and its accessories. Use this figure to
locate and identify the following parts:
1. The oven contains the electronics and heating elements
to burn the asphalt binder from the aggregate. The oven
includes an internal printer used to print sample data
and system status information. An integrated scale (not
shown) monitors mass loss throughout the burn cycle.
The oven’s exhaust duct vents fumes produced during
the ignition to a suitable ventilation system.