VERDER CARBOLITE GERO ABA 7/35B Manual

Installation, Operation and Maintenance Instructions
750°C Asphalt Binder Analyser - ABA Model: 35 Litres
ABA 7/35B
MEN-ABA735B-01 (17-10-2018)

Contents
This manual is for guidance on the use of the Carbolite Gero product specified on the
front cover. This manual should be read thoroughly before unpacking and using the
furnace or oven. The model details and serial number are shown on the back of this
manual. Use the product for the purpose for which it is intended.
1.0 Symbols and Warnings 7
1.1 Switches and Lights 7
1.2 General Warnings 7
2.0 Supplied Item List 9
2.1 Parts Supplied 9
2.2 Identifying the Parts 11
3.0 Installation 14
3.1 Unpacking and Handling 14
3.2 Siting and Setting Up 14
3.3 Tools Required 15
3.4 Fitting the Chimney 16
3.5 Ducting 16
3.6 Hot Sample Guard Assembly 17
3.7 Electrical Connections 17
3.8 Balance Installation 20
3.9 Installing Printer Paper 23
3.10 Calibrating Internal Balance 23
3.11 Connecting External Balance 24
4.0 Safety Features 25
4.1 Electric Shock Risk Lamps 25
4.2 Power Failure Safety Feature 25
4.3 Access to the Plenum Chamber 25
4.4 Door Lock Indication 'Lamps' on Touchscreen 26
4.5 Maintenance or Dismantling 26
5.0 ABA Operation 27
5.1 Switches - Control Panel 27
5.2 Door Operation and Status Display 27
5.3 General Operating Notes 28
5.4 Operator Safety 29
5.5 Touch-screen Main Menu 29
5.5.1 Table: Main Menu References 30
6.0 System Configuration Menu 31
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6.1 Accessing System Configuration Menu 31
6.1.1 Table: System Configuration Menu References 31
7.0 Running a Test 32
7.1 Set up 32
7.2 Selecting a Recipe 32
7.2.1 Table: Run Test Button Text 33
7.3 Pre-Test Requirements 33
7.3.1 Table: Pre Test Requirement Checks 33
7.4 Displayed Data Updates 33
7.4.1 Table: Test Status 35
7.5 Power Failure During Test 35
7.6 End of Test Trigger 35
7.7 Cancelling a Test 36
7.8 Weight Entry 36
7.9 Connecting an Adam Equipment™ External Balance 37
7.10 Connecting an Ohaus Explorer™ External Balance 37
7.10.1 Table: Ohaus Balance Settings 38
7.11 Connecting an Ohaus Explorer Pro™ External Balance 38
7.12 External Balance Configuration 39
7.13 Entering Weights 39
7.14 Weight Entry Error Checking 41
8.0 Tray Lift Calculation 42
8.1 Lift Correction 42
9.0 Access Levels 44
9.1 Setting Operator and Supervisor Access Levels 44
9.1.1 Table - Access Level Settings for Buttons (default factory settings) 45
10.0 Temperature Control 48
10.1 Main Chamber & After Burner 48
10.2 Heater On / Off Control 49
11.0 Setting the Date and Time 50
11.1 Date and Time Setting Screen 50
12.0 Printer Settings 52
12.1 Printer Setting Screen 52
13.0 Recipe Library Functions 54
13.1 Recipe Library Screen 54
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13.2 Copy Recipe 54
13.3 Edit Recipe 55
13.4 Delete Recipe 55
13.5 Run Recipe 55
14.0 Recipe Editor 56
14.1 Standard and Calibration Recipes 56
14.2 Recipe Name 58
14.3 Save Recipe 58
14.4 End Triggers 58
14.5 Initial Delay Time 58
14.6 Temperature Setpoint 58
14.7 Print Format 58
14.8 Calibration Format 59
14.9 Calibration Factor 59
14.10 Binder Content 59
15.0 Test Log Viewer 60
15.1 Test Log File 60
16.0 USB Memory Stick Data Transfer 62
16.1 File Types and Copy Direction 62
16.1.1 Table: USB Files 62
16.2 Screen Layout 63
16.2.1 Table: LED Colours 63
17.0 Internal Balance Commands 64
17.1 Balance Command Screen 64
17.2 Tare Command 64
17.3 Calibrate 65
17.4 Filter Setting 66
18.0 Language Selection 66
19.0 Reconfigure Voltage Settings For Alternative Electrical Supply 67
20.0 Temperature Calibration 68
20.1 Single Point Calibration 68
20.2 Dual Point Calibration 69
21.0 Maintenance 71
21.1 General Maintenance 71
21.2 Maintenance Schedule 71
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21.2.1 Cleaning 73
21.3 After Sales Service 73
21.4 Cleaning and Hours of Use Monitoring 73
21.5 Cleaning the Plenum Chamber & Fan Impeller 74
21.6 Recommended Spare Parts and Spare Parts Kit 75
22.0 Repairs and Replacements 76
22.1 Safety Warning - Disconnection from Power Supply 76
22.2 Safety Warning - Refractory Fibre Insulation 76
22.3 Temperature Controller Replacement 76
22.4 Solid-state Relay Replacement 78
22.5 Thermocouple Replacement 78
22.6 Element Replacement 78
22.7 Door Plug Replacement 78
22.8 Catch Tray Straightening 78
22.9 Consumables 79
23.0 ABA 7/35B - Interface Layout 80
24.0 Event Log Messages 81
25.0 Software Versions 83
25.1 Software Applications 83
26.0 Diagnostics 84
26.1 Diagnostic Screen 84
27.0 Fault Finding 85
A. The Furnace Main Chamber or After-burner Does Not Heat 85
B. The Main Chamber or After-burner is Slow to Heat Up 85
C. Furnace Overheats 86
D. Warning Lamp & Door Faults 87
E. Chimney Emits Smoke 87
F. Balance Errors 88
G. Fan Problems 89
H. Test Problems 89
I. Printer Problems 89
28.0 Circuit Diagram 90
29.0 Fuses 91
29.1 Customer Supply Fusing 91
29.2 Power Settings 91
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30.0 Specifications 92
30.1 Representations Covered by this Manual 92
30.2 Updates 92
30.3 Environment 92
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1.0 Symbols and Warnings
1.1 Switches and Lights
Instrument switch: when the instrument switch is operated the
temperature control circuit is energised.
Printer Switch: when the printer switch is operated power is being
supplied to the printer.
Safety Circuit Test Switch: activated to check the operation of the
two red warning lamps situated above the main chamber on the
right hand side of the ABA.
Heat light: the adjacent light glows or flashes to indicate that power
is being supplied to the elements.
Afterburner Heater Light: the adjacent light glows to indicate that
power is being supplied to the afterburner.
1.2 General Warnings
DANGER – Electric shock. Read any warning printed next to this
symbol.
WARNING: Risk of fatal injury.
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1.0 Symbols and Warnings

1.0 Symbols and Warnings
DANGER – Hot surface. Read any warning printed next to this
symbol.
WARNING: All surfaces of a product may be hot.
DANGER – Read any warning printed next to this symbol.
Caution – Double Pole/Neutral Fusing
8

2.0 Supplied Item List
2.1 Parts Supplied
The following items should be present. These should all be checked and identified as
soon as possible after receipt of the equipment. 2.2 shows photographs of many of the
parts for identification purposes.
Quantity Item
1 Asphalt Binder Analyser: ABA 7/35B
1 Chimney
(1) Optional Floor Stand (only if ordered)
(part number 00372-3-4000)
1 Adam Equipment Internal Balance Mechanism
1 Balance Pan Extension See Fig 1.
4Sample Baskets
(part number 00336-3-2039 - set of 2) See Fig 2.
2 Sample Basket Lids See Fig 2.
2
Sample of Sample Basket Clips (1 large, 1 small
per set)
(part number 35-090-044-0010)
2Sample Catch Trays
(part number 00336-3-2038)
1Sample Basket Loading Handle
(part number 00336-3-2041) See Fig 3.
1
Hot Sample Safety Guard
(part number 00336-3-2042 including handles &
fixing kit)
See Fig 4.
1 Hot Sample Guard Handle Fixing Kit See Figs 5. & Fig 6.
2 Door Lock Keys
1 Front Brick Cover See Fig 7.
1 Calibration Plate See Fig 8.
2Printer Paper Rolls (including 1 installed in printer)
(part number 22-222-356-0010) See Fig 28.
2Touch Screen Protector Films
(part number 31-019-200-0010)
1 Operating Instruction Manual
9
2.0 Supplied Item List

2.0 Supplied Item List
In addition, any spare parts ordered should be separately identified and put aside in
safe storage.
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2.2 Identifying the Parts
11
2.0 Supplied Item List

2.0 Supplied Item List
Fig 1 - Balance pan extension Fig 2 - Sample baskets on catch tray
with lids and clips
Fig 3 - Sample basket loading
handle
Fig 4 - Hot sample safety guards
(assembled)
Fig 5 - Hot sample safety guard
handle fixing kit
Fig 6 - Safety warning label for hot
sample safety guard
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Fig 7 - Front brick cover Fig 8 - Calibration Plate
Fig 9 - Functional parts of the ABA
13
2.0 Supplied Item List

3.0 Installation
3.0 Installation
3.1 Unpacking and Handling
When unpacking or moving the product, always lift by its base; do not use the door or
any other projecting cover or component to support the equipment when moving it. Use
a fork lift or pallet truck to move the product; position the product on a level surface and
use an adequate number of personnel to safely move the product into position.
Carefully remove any packing material from inside and around the product before use.
Avoid damaging the surrounding insulation when removing packing materials.
This product is fitted with a safety door lock; when there is no power
connected to the equipment the door has to be opened using the key supplied.
The keyhole is located on the right hand side of the case.
Lock the door again after checking and clearing the interior. See section 4.2.
NOTE: This product contains Refractory Ceramic Fibre (also known as
Alumino Silicate Wool - ASW). For precautions and advice on handling
this material see section 22.2.
3.2 Siting and Setting Up
Place the product on a level surface in a well ventilated area.
Site away from other sources of heat and on a non-flammable surface that is resistant
to accidental spillage or hot materials.
The surface on which the equipment is mounted should be stable and not subject to
movement or vibrations.
The height of the mounting surface is important to avoid operator strain when loading
and unloading samples.
Unless otherwise stated elsewhere in this manual, ensure that there is at least 150
mm of free space around the back and sides of the product. Clear space is required
above the product to dissipate heat.
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If sited in a prefabricated or mobile laboratory additional stiffening of the floor may be
required to ensure stability of the internal weighing system.
If the optional metal stand (part number 00372-3-4000) is supplied, this is best placed
on a solid (concrete) floor.
Ensure that the product is placed in such a way that it can be quickly switched off or
disconnected from the electrical supply.
Under no circumstances should any objects be placed on top of the product.
Always ensure that any vents on the top of the product are clear of any
obstruction. Always ensure all cooling vents and cooling fans (if fitted) are
clear of any obstruction.
3.3 Tools Required
l10 mm spanner
l12 mm spanner
lCross point screwdriver
lFlat blade screwdriver
lAllen key (supplied)
l5 kg calibration mass (not supplied)
lSpirit level (supplied)
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3.0 Installation

3.0 Installation
3.4 Fitting the Chimney
lRemove the chimney panel, (see Fig 10.)
lFasten the chimney to the top of the product using the screws provided, (see Fig 12.)
lReplace the chimney panel, (see Fig 11.)
Fig 10 - Remove the
chimney panel Fig 11 - Replace the
chimney panel
Fig 12 - Chimney
screws
3.5 Ducting
The chimney must either be placed under a powered exhaust hood, or connected
directly to a 76 mm duct (not supplied) to the outside of the building; any such duct
must NOT have powered extraction.
The fumes should be ducted by either of the above methods to at least 1 metre above
the level of the building.
Rules for ducting:
lDucting diameter must be 76 mm or more.
lDucting must be 76 mm where it connects to the chimney.
lDucting length must not exceed 3 metre for 76 mm diameter; for longer lengths con-
sult a ducting engineer.
lFlexible ducting, if used, must be suitable for exhaust gas extraction.
lIf an extraction fan is fitted an extraction hood is required with free flow of air
around the chimney.
lDo not connect more than one product to a single duct. (Exception: where a fanned
duct with hoods is used)
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Fig 13 - Ducting Schematic
3.6 Hot Sample Guard Assembly
The hot sample safety guard is supplied as a kit comprising the guard, the handles and
fixing screws and a warning label and fixing screws. See Fig 4. to Fig 6. to assemble the
handles and the warning label to the guard.
3.7 Electrical Connections
Connection by a qualified electrician is recommended.
Model ABA 7/35B is designed for connection to a range of power
supplies with the minimum of circuit modifications. It is initially supplied
to suit the voltage for which it was ordered.
Look at the rating label before connection to check the electrical supply voltage and
frequency for which the unit is configured. If there is a difference between the actual
supply and the rating label, reconnect the wires between the terminal block and the
EMC filters according to the appropriate diagram below.
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3.0 Installation

3.0 Installation
If there is a need to connect the ABA to a voltage other than that shown on the label
when it is delivered, it is essential to first ensure that wiring configuration shown in table
below is configured correctly for the intended new mains supply.
The electrical supply should be fused at the next standard size equal to or higher than
the rated current. A table of fuse ratings is given in section 29.0
Either wire directly to an isolator or fit with a line plug. An isolating switch should operate
on both conductors (single phase) or on all live conductors (three phase); it should be
within reach of the operator. A line plus should be easily removable and should b within
reach of the operator.
The electrical supply MUST incorporate an earth (ground).
Failure to wire to the appropriate diagram may damage the ABA.
18

Fig 14 - Schematic for Mains Electrical Connections
19
3.0 Installation

3.0 Installation
3.8 Balance Installation
Remove the balance from its packing and isolate the ABA from the electrical supply.
Remove both lower side covers.
With the furnace in its intended final location, place the spirit level on the balance
location plate, as shown in Fig 15.
If the plate is not level then adjust the whole furnace, either by placing suitable shims
under the furnace feet, or adjusting the stand legs.
Open the chamber door and make sure that there are no obstructions, such as loose
packing or insulation material in the four holes in the chamber hearth that the legs of
the balance pan extension pass through.
Position the front brick cover over the front of the chamber (see Fig 16.).
In the base compartment, loosen the four screws holding the balance location plate
using a 10mm spanner.
Partly insert the balance into the left side opening of the furnace with the ‘front’ sloping
portion of the balance facing towards the rear of the furnace (see Fig 17.). Connect the
combined balance data and power supply lead marked ‘internal’ to the balance body,
lightly tightening the plug’s retaining screws, then connect the balance’s earth cable to
the spade connector in the upper rear part of the recess (see Fig 19. and Fig 20.).
Open the door lock with the key provided. Insert the balance pan extension into the
main chamber with the extension legs fitting through the four holes in the chamber
hearth (Fig 24. to Fig 25.). Note that the front edge of the extension is folded down.
Fasten the balance pan extension to the balance using the four screws and Allen key
supplied (see Fig 26. to Fig 27.).
Place the sample tray and spirit level in the furnace chamber, as shown in Fig 22.
Adjust the threaded balance legs until the tray is level.
The balance pan extension legs should pass centrally through the holes in the chamber
floor (see Fig 28.); this can be seen from the balance side access panel (see Fig 21.).
If it is necessary to adjust the balance position, slacken the four screws holding the
location plate. Gently tap or slide the plate until all four legs are central, then retighten
the screws.
Note that for accurate and reliable weight measurement, there must be no
mechanical contact between any fixed parts of the furnace and the balance pan
extension. The method described above is designed to ensure this across the entire
operating temperature range.
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